Cylindrical mixed material inductor and cylindrical two-path magnetic integrated inductor
By designing a cylindrical hybrid material inductor and using double-layer vertically wound flat aluminum wire or copper-clad aluminum wire windings and a hybrid magnetic core, the problem of limited automated winding of toroidal inductors was solved, achieving low-cost and high-efficiency inductor production.
Patent Information
- Application Number
- CN202511546868.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-28
- Publication Date
- 2025-12-12
AI Technical Summary
Existing toroidal inductors suffer from limitations in automated winding and poor shape consistency in the photovoltaic and energy storage industries, resulting in limited production capacity and high costs. Copper wire resources are scarce, necessitating an alternative that can be automated, has lower costs, and is more efficient.
The inductor uses a cylindrical hybrid material and employs double-layer vertically wound flat aluminum wire or double-layer vertically wound flat copper-clad aluminum wire windings. It combines different core materials to form a hybrid core and is designed as a closed magnetic circuit, including a cylindrical central core, a plate yoke core, and a toroidal core, which is suitable for automated production.
It achieves automated production, reduces costs, improves production efficiency, balances eddy current losses and heat dissipation capabilities, and meets the performance requirements of different application scenarios.
Smart Images
Figure CN121122891A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to a cylindrical hybrid material inductor, in particular to a cylindrical hybrid material inductor prepared using a hybrid material. BACKGROUND
[0002] With the large-scale development and application of photovoltaic and energy storage industries, the related component industry has also made great progress. As the main parts of the raw material cost, the demand for cost reduction and efficiency improvement has become increasingly urgent. In addition, copper wire has been used as an excellent conductor in this field for many years, but the gradual depletion and uneven distribution of copper resources have increasingly restricted the related industry. At the same time, although the ring inductor is widely used in this industry due to its low cost and high reliability, the limited production capacity and poor shape consistency caused by the inability of the ring inductor to be automatically wound have increasingly restricted the related industry. SUMMARY
[0003] In order to provide a product that can be automatically produced, has lower cost, higher efficiency, and can realize pin-to-pin replacement without changing the shape of the installation shell, the present application provides a cylindrical hybrid material inductor. The technical solution of the present application is that there is a cylindrical center column magnetic core and a double-layer vertical winding flat aluminum wire winding or a double-layer vertical winding flat copper-clad aluminum wire winding. Each of the two ends of the cylindrical magnetic core is provided with a plate part yoke magnetic core. The thickness of the plate part yoke magnetic core is less than or equal to 0.35 times the diameter of the cylindrical magnetic core. There are through holes or notches on the plate part yoke magnetic core, which are used for wire head wire outlet, pouring into glue and blowing heat dissipation. There is an annular magnetic core on the outside, which forms a closed magnetic circuit with the cylindrical magnetic core and the plate parts at both ends thereof. The inner diameter of the annular magnetic core is greater than or equal to 1.6 times the diameter of the cylindrical magnetic core.
[0004] The present application also provides a cylindrical two-way magnetic integrated inductor. The technical solution is that there are two cylindrical center column magnetic cores in series and a double-layer vertical winding flat aluminum wire winding or a double-layer vertical winding flat copper-clad aluminum wire winding. Each of the two ends and the series end of the two cylindrical center column magnetic cores is provided with a plate part yoke magnetic core. The thickness of the plate part yoke magnetic core is less than or equal to 0.35 times the diameter of the cylindrical center column magnetic core. There are through holes or notches on the plate part yoke magnetic core, which are used for wire head wire outlet, pouring into glue and blowing heat dissipation. There is an annular magnetic core on the outside, which forms a closed magnetic circuit with the cylindrical center column magnetic core and the plate part yoke magnetic cores at both ends thereof. The inner diameter of the annular magnetic core is greater than or equal to 1.6 times the diameter of the cylindrical center column magnetic core.
[0005] The beneficial effects of the present application are: the double-layer vertical winding flat aluminum wire winding or double-layer vertical winding flat copper-clad aluminum wire winding not only makes the winding height not too high when the number of turns is large, but also achieves a good trade-off between eddy current loss, heat dissipation capacity and production efficiency, and the double-layer winding structure makes the outgoing wire head located on the same side, facilitating the structural design of magnetic integration. At the same time, the mixed magnetic core composed of two or more kinds of magnetic core materials can maximize the use of the price and performance advantages of each material according to different application scenarios to form the optimal solution. Each component of the inductor of the present application can be independently prefabricated, and the production of the entire product can be completed through automatic assembly, so the production efficiency is high. BRIEF DESCRIPTION OF DRAWINGS
[0006] Figure 1 is a schematic diagram of the magnetic circuit structure of the iron core;
[0007] Figure 2 is a structure exploded view of the present application;
[0008] Figure 3 is a structure exploded view of two yoke iron placed with a 90° offset.
[0009] Figure 4 is a structure exploded view of the two different diameter plate yoke iron magnetic cores of the present application;
[0010] Figure 5 is a structure exploded view of the cylindrical two-way magnetic integrated inductor of the present application;
[0011] In the figure, 1: cylindrical center column magnetic core; 2: double-layer vertical winding flat aluminum wire winding or double-layer vertical winding flat copper-clad aluminum wire winding; 3: plate yoke iron magnetic core; 31: through hole; 32: blind hole; 4: ring-shaped magnetic core; 5: wire head; D3-1: large diameter (plate yoke iron magnetic core); D3-2: small diameter (plate yoke iron magnetic core); D4: inner diameter (ring-shaped magnetic core). DETAILED DESCRIPTION
[0012] This invention provides a cylindrical hybrid material inductor constructed using double-layer vertically wound flat aluminum wire or double-layer vertically wound flat copper-clad aluminum wire as the conductor material and a hybrid magnetic circuit composed of various magnetic cores. While aluminum, as a good conductor of electricity, is slightly inferior to copper in conductivity, it is far superior in terms of cost, production volume, and mineral reserves. Therefore, using large-section aluminum wire or copper-clad aluminum wire can achieve a balance between cost reduction and efficiency improvement. Since the resistivity of aluminum wire is slightly greater than that of copper wire, the cross-sectional area of the aluminum wire or copper-clad aluminum wire needs to be larger than that of the copper wire. The hardness and ductility of metallic aluminum determine that the minimum thickness of the flat aluminum wire currently used in vertical winding processes is approximately 1 mm. Therefore, when increasing the amount of aluminum wire to improve efficiency and reduce overall cost, double-layer vertically wound flat aluminum wire windings or double-layer vertically wound flat copper-clad aluminum wire windings are required. Using double-layer vertically wound windings not only prevents the winding height from becoming too high when the number of turns is large, but also achieves a good balance between eddy current losses, heat dissipation capacity, and manufacturing processes. Because the unit volume cost of aluminum is lower than that of iron core material, the more aluminum used while meeting inductor performance requirements, the lower the overall cost of the inductor. This necessitates a smaller cylindrical core cross-section and a larger winding window area. However, considering the inductor's shape and manufacturing limitations, a ratio between the cross-sectional area of the cylindrical core and the winding window area between the toroidal core and the cylindrical core is typically found to balance cost and efficiency when the inner diameter of the toroidal core is greater than or equal to 1.6 times the diameter of the cylindrical core. Furthermore, this invention employs two or more core materials to form a hybrid core, maximizing the price and performance advantages of each material to create an optimal solution for different application scenarios.
[0013] When different core materials are used for the cylindrical center core and the plate yoke core of a cylindrical hybrid material inductor, the continuity of magnetic flux must be maintained at the interface between the two cores. Therefore, the product of the maximum magnetic flux density of the cylindrical center core and its cross-sectional area must equal the product of the maximum magnetic flux density of the plate yoke core and its cross-sectional area. Typically, to reduce DC resistance, a smaller cross-sectional area is required for the cylindrical center core; therefore, a core material with high saturation magnetic flux density is used to meet the inductor's energy storage requirements. The plate yoke core, located outside the coil, is less constrained by the coil's dimensions and can have a larger cross-sectional area. While maintaining magnetic flux continuity, it can also provide some magnetic shielding; therefore, a material with high permeability and low magnetic flux density can be used. Figure 1 As shown, the cylindrical central core has a diameter D and a maximum magnetic flux density Bc = 1.2T. The plate-type yoke core has a thickness ht and a maximum magnetic flux density Be = 0.75T. The continuity requirement for the magnetic flux is 0.25 * D. 2*π*Bc=D*π*ht*Be, can get ht=0.4D. Considering the influence of magnetic flux diffusion, the simulation can get that about 15% of the magnetic flux on the cylindrical center column magnetic core will diffuse to the winding window, and the actual magnetic flux passing through the plate yoke magnetic core is only about 85% of the magnetic flux on the cylindrical center column magnetic core, so ht≈0.4D*85%=0.34D. Taking into account the performance error of different magnetic cores, the thickness of the plate yoke magnetic core is generally less than or equal to 0.35 times the diameter of the cylindrical center column magnetic core.
[0014] According to the above solution and research data, the structure of the present application is as shown in Figure 2 、 3 The structure of the present application is as follows: a cylindrical center column magnetic core 1 is provided with a double-layer vertical winding flat aluminum wire winding or a double-layer vertical winding flat copper-clad aluminum wire winding 2; each end of the cylindrical center column magnetic core 1 is provided with a plate yoke magnetic core 3, the thickness of the plate yoke magnetic core 3 is less than or equal to 0.35 times the diameter of the cylindrical center column magnetic core 1, and the plate yoke magnetic core 3 is provided with a through hole 31 or a notch, and the through hole 32 or the notch is used for wire head 5 wire outlet, pouring into glue and blowing heat dissipation; an annular magnetic core 4 is provided on the outside, and the annular magnetic core 4 and the cylindrical center column magnetic core 1 and the plate yoke magnetic cores 3 at both ends thereof form a closed magnetic circuit, and the inner diameter of the annular magnetic core 4 is greater than or equal to 1.6 times the diameter of the cylindrical center column magnetic core 1. As an optimization scheme, the present application can adopt any of the following improvements:
[0015] The cylindrical center column magnetic core 1 is composed of one or more segments, and air gaps are provided between the segments,
[0016] The plate yoke magnetic core 3 is made of a magnetic powder core material, including but not limited to iron-silicon, iron-silicon-aluminum, etc.,
[0017] As shown in Figure 3 The plate yoke magnetic core 3 is provided with a blind hole 32 for positioning the cylindrical center column magnetic core 1, and the through holes 31 or notches provided on the two plate yoke magnetic cores 3 are placed in a staggered manner, and the preferred staggered angle is 90 degrees,
[0018] The material of the annular magnetic core 4 on the outside is ferrite, amorphous, nanocrystalline or iron-silicon-aluminum; the annular magnetic core 4 on the outside is composed of one or more segments;
[0019] The product of the magnetic permeability and the cross-sectional area of the material of the annular magnetic core 4 on the outside is greater than 2 times the product of the magnetic permeability and the cross-sectional area of the material of the cylindrical center column magnetic core 1, so as to achieve better magnetic shielding performance and reduce the coupling and interference between inductors.
[0020] In assembling the inductor, first, the pre-prepared double-layer vertical winding flat aluminum wire winding or double-layer vertical winding flat copper-clad aluminum wire winding 2 is sleeved on the cylindrical center column magnetic core 1, then the plate yoke magnetic core 3 is assembled on both ends of the cylindrical center column magnetic core 1 after being glued, and finally the ring-shaped magnetic core 4 is sleeved and glued and baked. When the cylindrical center column magnetic core 1 is composed of two sections, the two plate yoke magnetic cores 3 and the two sections of the cylindrical center column magnetic core 1 are respectively bonded together to form two T-shaped magnetic cores, and then the pre-prepared double-layer vertical winding flat aluminum wire winding or double-layer vertical winding flat copper-clad aluminum wire winding 2 and the ring-shaped magnetic core 4 are sleeved and glued and baked.
[0021] As shown in Figure 4 Preferably, the diameters of the two plate yoke magnetic cores 3 are different and are greater and smaller than the inner diameter D4 of the ring-shaped magnetic core 4; in assembling the inductor, first, the cylindrical center column magnetic core 1 and the plate yoke magnetic core 3 with the large diameter D3-1 are bonded together, then the pre-prepared double-layer vertical winding flat aluminum wire winding or double-layer vertical winding flat copper-clad aluminum wire winding 2 is sleeved, and then the plate yoke magnetic core 3 with the small diameter D3-2 is bonded and sleeved into the ring-shaped magnetic core 4 from top to bottom after being glued and baked. The plate yoke magnetic core 3 is provided with a blind hole 32 for positioning the cylindrical center column magnetic core 1.
[0022] As shown in Figure 5 The application further provides a cylindrical two-way magnetic integrated inductor, which comprises two cylindrical center column magnetic cores 1 connected in series and wound with double-layer vertical winding flat aluminum wire windings or double-layer vertical winding flat copper-clad aluminum wire windings 2; each of the two ends and the series end of the two cylindrical center column magnetic cores 1 is provided with a plate yoke magnetic core 3, the thickness of the plate yoke magnetic core 3 is less than or equal to 0.35 times the diameter of the cylindrical center column magnetic core 1, and the plate yoke magnetic core 3 is provided with a through hole 31 or a notch, which is used for wire outlet, glue filling and blowing heat dissipation; the outer side is respectively provided with a ring-shaped magnetic core 4, which forms a closed magnetic circuit together with the cylindrical center column magnetic core 1 and the plate yoke magnetic cores 3 at both ends, and the inner diameter of the ring-shaped magnetic core 4 is greater than or equal to 1.6 times the diameter of the cylindrical center column magnetic core 1. Figure 4 As shown in
[0023] The above specific embodiments are only exemplary and are intended to enable those skilled in the art to better understand the patent, and cannot be understood as a limitation on the scope of the patent; any changes or modifications made to the technical content according to the technical solutions disclosed in the patent are substantially the same or equivalent, and fall within the scope of the patent.
Claims
1. A cylindrical hybrid material inductor, characterized by: There is a cylindrical center column magnetic core (1) and a double-layer vertical winding flat aluminum wire winding or double-layer vertical winding flat copper-clad aluminum wire winding (2) wound thereon; each end of the cylindrical center column magnetic core (1) is provided with a plate yoke magnetic core (3), the thickness of the plate yoke magnetic core (3) is less than or equal to 0.35 times the diameter of the cylindrical center column magnetic core (1), and the plate yoke magnetic core (3) is provided with a through hole (31) or a notch, the through hole (31) or the notch is used for wire head (5) wire outlet, pouring into glue and blowing heat dissipation; there is a ring-shaped magnetic core (4) on the outside, which forms a closed magnetic circuit with the cylindrical center column magnetic core (1) and the plate yoke magnetic cores (3) at both ends thereof, and the inner diameter of the ring-shaped magnetic core (4) is greater than or equal to 1.6 times the diameter of the cylindrical center column magnetic core (1).
2. The cylindrical hybrid material inductor of claim 1, wherein: The material of the cylindrical center column magnetic core (1) and the plate yoke magnetic core (3) is a magnetic powder core material.
3. The cylindrical hybrid material inductor of claim 2, wherein: The magnetic powder core material is iron-silicon or iron-silicon-aluminum.
4. The cylindrical hybrid material inductor of claim 1, wherein: The cylindrical center column magnetic core (1) is composed of one or more segments, and air gaps are arranged between the segments.
5. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The plate yoke magnetic core (3) is provided with a blind hole (32) for positioning the cylindrical center column magnetic core (1).
6. The cylindrical mixed-material inductor of claim 1, wherein: The through holes (31) or notches opened on the two plate yoke magnetic cores (3) are placed in a staggered manner.
7. The cylindrical hybrid material inductor of claim 6, wherein: The staggered angle of the through holes (31) or notches placed in a staggered manner is 90 degrees.
8. The cylindrical hybrid material inductor of claim 1, wherein: The material of the ring-shaped magnetic core (4) is ferrite, amorphous, nanocrystalline or iron-silicon-aluminum.
9. The cylindrical hybrid material inductor of claim 1, wherein: The ring-shaped magnetic core (4) is composed of one or more segments.
10. The cylindrical hybrid material inductor of claim 1, wherein: The product of the magnetic permeability and the cross-sectional area of the material of the ring-shaped magnetic core (4) is greater than 2 times the product of the magnetic permeability and the cross-sectional area of the material of the cylindrical center column magnetic core (1).
11. A cylindrical hybrid material inductor as in claim 1, wherein: The diameters of the plate yoke magnetic cores (3) are different, wherein the small diameter (D3-2) is smaller than the inner diameter (D4) of the ring-shaped magnetic core (4), and the large diameter (D3-1) is greater than the inner diameter (D4) of the ring-shaped magnetic core (4).
12. A cylindrical two-way magnetic integrated inductor, characterized by: There are two cylindrical center column magnetic cores (1) and double-layer vertical winding flat aluminum wire windings or double-layer vertical winding flat copper-clad aluminum wire windings (2) wound thereon in series; each end of the two cylindrical center column magnetic cores (1) and the series end is provided with a plate yoke magnetic core (3), the thickness of the plate yoke magnetic core (3) is less than or equal to 0.35 times the diameter of the cylindrical center column magnetic core (1), and the plate yoke magnetic core (3) is provided with a through hole (31) or a notch, the through hole (31) or the notch is used for wire head (5) wire outlet, pouring into glue and blowing heat dissipation; there is a ring-shaped magnetic core (4) on the outside, which forms a closed magnetic circuit with the cylindrical center column magnetic cores (1) and the plate yoke magnetic cores (3) at both ends thereof, and the inner diameter of the ring-shaped magnetic core (4) is greater than or equal to 1.6 times the diameter of the cylindrical center column magnetic core (1).
13. The cylindrical two-way magnetic integrated inductor of claim 12, wherein: The diameter of the plate yoke magnetic core (3) at the series end is a large diameter (D3-1), which is greater than the inner diameter (D4) of the ring-shaped magnetic core (4), and the diameter of the plate yoke magnetic core (3) at both ends is a small diameter (D3-2), which is smaller than the inner diameter (D4) of the ring-shaped magnetic core (4).