Power inductor with floating copper ribbon terminal

Abstract

The application discloses a power inductor with a floating copper bar terminal and belongs to the technical field of inductors. The power inductor comprises a magnetic core, a coil, an L-shaped copper bar terminal, a base and a cover plate. The L-shaped copper bar terminal is provided with a threaded hole on one side and a T-shaped structure on the other side. The threaded hole is used for the threaded connection of a rivet nut and the threaded hole is provided with a through hole for the welding of a coil lead. The base is provided with a mesh structure and is full of holes. The base is provided with a counterbore which is matched with the T-shaped structure. The depth of the counterbore is greater than the height of the T-shaped structure. The base is provided with a boss. After the cover plate is fixed to the base, a floating space is formed between the T-shaped structure and the cover plate. The L-shaped copper bar terminal can move up and down in the space. The application can compensate for assembly deviation through the floating copper bar terminal, avoid the deformation of a PCB, improve the heat dissipation effect through the mesh structure of the base, save the soft wire and reduce the cost and save the space, has high assembly reliability and is suitable for power electronic equipment such as a photovoltaic inverter and an alternating current energy storage device.

Description

Technical Field

[0001] This invention relates to a power inductor with floating copper busbar terminals, belonging to the field of power inductor technology. Background Technology

[0002] An inductor, also known as a reactor or choke, is a component that converts electrical energy into magnetic energy based on the principle of electromagnetic induction. In AC circuits, it impedes the flow of current and is commonly used as a current blocker, transformer, AC coupling agent, and load. Power inductors are important components of photovoltaic inverters and AC energy storage devices, primarily serving to filter, store energy, and protect circuits. Combined with relevant electronic devices, they can convert direct current (DC) to alternating current (AC).

[0003] Inductors are generally composed of a magnetic core, a coil, lead wires, and terminals. Enameled wire is wound around the magnetic core to form a coil. The start and end leads are connected by soldering with lead wires, and the end is soldered with terminals. When the customer uses it, the inductor is placed inside the inductor box, then glue is applied, and the start and end leads of the inductor are led out by lead wires and locked to the customer's PCB board through the terminals.

[0004] Traditional inductors rely on flexible wires and connecting terminals to extend their leads and secure them to the PCB. Flexible wires are expensive, require insulation at the solder joints, and result in slow production and long lead times. The long wires also take up internal space in the inverter, and incorrect wiring by the customer can easily lead to damage. Some manufacturers have directly soldered enameled wires to copper busbar terminals. However, since the copper busbar terminals are completely fixed to the base and cannot move up or down, the PCB is subjected to stress when locked to the inductor's copper busbar due to height differences or dimensional deviations in the structural components. This stress on the entire PCB can damage the soldered electronic components, reducing their lifespan.

[0005] Therefore, there is an urgent need for a new type of power inductor structure to solve the problems of high cost, large space occupation, easy installation errors, and PCB board deformation under stress in the existing technology. Summary of the Invention

[0006] To overcome the shortcomings of the prior art, this invention provides a power inductor with floating copper busbar terminals, which solves the problems of high cost, error susceptibility, and large space occupation of traditional soft wire lead-out structures. At the same time, it overcomes the defects of PCB board deformation caused by the existing copper busbar terminal fixing structure, realizes low-cost and compact design of power inductors, and improves product assembly reliability and service life.

[0007] The present invention is achieved through the following technical solution: a power inductor with floating copper busbar terminals, comprising a magnetic core, a coil wound on the magnetic core, L-shaped copper busbar terminals, a base and a cover plate.

[0008] A nut is crimped on one side of the L-shaped copper busbar terminal, and a through hole is provided on this side for the coil lead wire to pass through and be welded; the other side of the L-shaped copper busbar terminal is designed as a T-shaped structure.

[0009] The base is a mesh structure with holes on its surface. A countersunk hole is provided on the base, which is fitted with the T-shaped structure of the L-shaped copper busbar terminal with a clearance. The depth of the countersunk hole is greater than the height of the T-shaped structure. A boss is provided on the base. The cover plate is fixedly connected to the base, so that a gap is formed between the T-shaped structure and the cover plate. This gap is the vertical floating space of the L-shaped copper busbar terminal.

[0010] The coil's lead wires pass through the through holes of the L-shaped copper busbar terminal and are welded and fixed. The T-shaped structure of the L-shaped copper busbar terminal is inserted into the countersunk hole of the base, and the L-shaped copper busbar terminal can move up and down in the floating space.

[0011] Furthermore, the cover plate is fixedly connected to the base by means of a hot riveting boss.

[0012] Furthermore, the cover plate is designed with a snap-fit ​​mechanism, and is fixedly connected to the base through a snap-fit ​​engagement.

[0013] Furthermore, the T-shaped structure of the L-shaped copper busbar terminal is fitted with the countersunk hole of the base with a clearance, and the T-shaped structure does not shift left or right within the countersunk hole.

[0014] Furthermore, the L-shaped copper busbar terminal is made of T2 copper, and its surface is treated with an electroplating tin process.

[0015] Furthermore, the nut is press-riveted onto the L-shaped copper busbar terminal using a press.

[0016] Furthermore, the nut is an M4 nut made of stainless steel.

[0017] When assembling and using the power inductor of this invention, the end customer places the inductor into the cavity of the inductor box and applies potting compound to completely fix the inductor. Then, a PCB board is placed on top of the inductor box and secured to the nuts on the L-shaped copper busbar terminals using screws.

[0018] Due to dimensional deviations in structural components and assembly gaps, a certain gap is reserved between the inductor copper busbar and the PCB board. During the screw tightening process, the L-shaped copper busbar terminals can be pulled up and floated within the floating space formed by the T-shaped structure and the cover plate, thus completely adhering to the PCB board and preventing the PCB board from deforming downwards due to force, ensuring the service life of the electronic components on the PCB board.

[0019] The beneficial effects of this invention are: by using the gap fit design between the L-shaped copper busbar terminal and the base, and with the cover plate limiting the space to form a floating space, the copper busbar terminal can move up and down, effectively compensating for dimensional deviations and gaps during the assembly process, avoiding PCB board deformation under stress, protecting electronic components, and improving product reliability.

[0020] The base adopts a mesh structure and is full of holes, which saves materials and makes the potting compound flow more easily and fully adhere to the inductor. Heat can be quickly transferred to the heat dissipation teeth of the inductor box through the thermally conductive adhesive, improving the heat dissipation effect and reducing the temperature rise of the product.

[0021] The L-shaped copper busbar terminals directly replace the traditional soft wire lead-out structure, eliminating the need for wire materials and welding processes, reducing material and labor costs, and saving internal wiring space in the inverter, thus achieving a compact product design. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the structure of the L-shaped copper busbar terminal of the present invention; Figure 3 This is a schematic diagram of the structure of the inductor mesh base of the present invention; Figure 4 This is an assembly diagram of the present invention; Figure 5 for Figure 4 AA section view; Figure 6 for Figure 5 Schematic diagram at point B; Figure 7 This is a schematic diagram of the assembly structure of the present invention and the PCB board.

[0024] In the diagram: 1-L-type copper busbar terminal, 11-through hole, 12-T-type structure, 13-nut, 2-base, 21-countersunk hole, 22-bore, 23-hole, 3-cover plate. Detailed Implementation

[0025] like Figures 1 to 7 The power inductor shown includes a magnetic core, a coil wound on the magnetic core, an L-shaped copper busbar terminal 1, a base 2, and a cover plate 3.

[0026] The L-shaped copper busbar terminal 1 is made of T2 copper with a tin-plated surface, which improves its anti-oxidation properties and facilitates soldering to the coil leads. One side of the L-shaped copper busbar terminal 1 is press-fitted with a stainless steel M4 nut 13. The press-fitted nut provides a secure connection, preventing detachment and slippage, and allows customers to easily tighten the PCB board with screws. A through-hole 11 is also provided on this side, through which the coil leads pass and are soldered. The other side of the L-shaped copper busbar terminal 1 features a T-shaped structure 12, used to engage with the base 2 to prevent detachment.

[0027] The base 2 is a mesh structure made of flame-retardant engineering plastic, with holes 23 all over its surface. A countersunk hole 21 is provided on the base 2, the depth of which is greater than the height of the T-shaped structure 12. The T-shaped structure 12 is inserted into the countersunk hole 21, forming a clearance fit to ensure that the T-shaped structure 12 does not shift left or right. A boss 22 is provided on the base 2. The cover plate 3 can be fixed by hot riveting the boss 22 or by a snap-fit ​​structure to the base 2. After the cover plate 3 is fixed, a floating space of 0.5-3mm is formed between the T-shaped structure 12 and the cover plate 3, allowing the L-shaped copper busbar terminal 1 to move up and down.

[0028] When using, place the inductor into the inductor box and fix it with glue. Then, tighten the PCB board onto the nut 13 with the screw. During the tightening process, the L-shaped copper busbar terminal 1 floats up with the tension of the screw and fits completely against the PCB board to prevent the PCB board from deforming under stress.

Claims

1. A power inductor with floating copper busbar terminals, characterized in that: It includes a magnetic core, a coil wound on the magnetic core, an L-shaped copper busbar terminal (1), a base (2) and a cover plate (3); one side of the L-shaped copper busbar terminal (1) is riveted with a nut (13), and the side is provided with a through hole (11) for the coil lead wire to pass through and be welded; the other side of the L-shaped copper busbar terminal (1) is provided with a T-shaped structure (12). The base (2) is a mesh structure with holes (23) on its surface. A countersunk hole (21) is provided on the base (2). The countersunk hole (21) is fitted with the T-shaped structure (12) of the L-shaped copper busbar terminal (1) with a clearance, and the depth of the countersunk hole (21) is greater than the height of the T-shaped structure (12). A boss (22) is provided on the base (2). The cover plate (3) is fixedly connected to the base (2), so that a gap is formed between the T-shaped structure (12) and the cover plate (3). This gap is the vertical floating space of the L-shaped copper busbar terminal (1). The lead wires of the coil pass through the through hole (11) of the L-shaped copper busbar terminal (1) and are welded and fixed. The T-shaped structure (12) of the L-shaped copper busbar terminal (1) is inserted into the countersunk hole (21) of the base (2). The L-shaped copper busbar terminal (1) can move up and down in the floating space.

2. The power inductor with floating copper busbar terminals according to claim 1, characterized in that: The cover plate (3) is fixedly connected to the base (2) by means of hot riveting boss (22).

3. A power inductor with floating copper busbar terminals according to claim 1, characterized in that: The cover plate (3) is designed as a snap-fit ​​and is fixedly connected to the base (2) by snap-fit.

4. A power inductor with floating copper busbar terminals according to claim 1, characterized in that: The T-shaped structure (12) of the L-shaped copper busbar terminal (1) is fitted with the countersunk hole (21) of the base (2) with clearance, and the T-shaped structure (12) does not shift left or right within the countersunk hole (21).

5. A power inductor with floating copper busbar terminals according to claim 1, characterized in that: The L-shaped copper busbar terminal (1) is made of copper T2, and its surface is treated with electroplating tin.

6. A power inductor with floating copper busbar terminals according to claim 1, characterized in that: The nut (13) is pressed and riveted onto the L-shaped copper busbar terminal (1) by a press.

7. A power inductor with floating copper busbar terminals according to claim 6, characterized in that: The nut (13) is an M4 nut made of stainless steel.

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