Integrally-formed inductor

Abstract

The utility model relates to the technical field of inductance elements, and provides an integrally formed inductor, which comprises a magnet structure and a conductor coil, the magnet structure comprises a third magnet and a prefabricated first magnet, the conductor coil is wound on the outer surface of the magnet structure, the third magnet is coated on the outer surfaces of the conductor coil and the magnet structure, and the first magnet and the second magnet are prefabricated. The conductor coil is not exposed, the conductor coil is of an integrally-formed cuboid structure, the first magnet is a middle column with the section of a rectangular structure, the conductor coil is a rectangular coil matched with the first magnet, the four corners of the rectangular section of the first magnet are provided with chamfers, and the chamfers R are larger than 2 mm. And the conductor coil is provided with a chamfer matched with the first magnet. By means of the technical scheme, the problems that an existing inductor adopts a non-integrally-formed circular middle column, a copper wire is exposed, the magnetic shielding effect is poor easily, magnetic lines of force can be diffused into the surrounding environment, and normal operation of surrounding components is interfered are solved.

Description

Technical Field

[0001] The utility model relates to the technical field of inductor components, and specifically to an integrally formed inductor. Background Art

[0002] With the rapid development of power electronics technology, inductors, as a very important basic component, have been used more and more widely. While the application areas of inductors are constantly expanding, the market has also put forward higher and higher requirements on the performance of inductors, such as high saturation, low loss, high reliability, high anti-interference ability, and the smallest possible volume occupation.

[0003] Traditional ferrite or metal soft magnetic material assembled inductors usually have the problem of poor reliability. This is because such inductors are assembled from some loose components, which are prone to loosening and falling off, resulting in circuit failure and system failure. At the same time, the space utilization rate is low, there will be many gaps between the coil and the magnetic core, which are not fully and effectively utilized, which leads to the increase of the overall volume of the inductor.

[0004] Chinese patent CN115440474A discloses an integrally formed inductor, which solves the problem of increasing the overall volume of the inductor by filling a mold with a soft magnetic slurry to form a second magnetic body. Chinese patent CN219105891U discloses a composite inductor, which provides a gap between a first center column and a second center column, and then fills a third magnetic core with a low magnetic permeability and high saturation magnetic slurry, so that there is no insulating air gap between the magnetic cores, and the reliability is high.

[0005] The existing one-piece molded inductor has made improvements in the second inductor one-piece molding and the gap of the middle column, but it is not difficult to find that the middle column still uses the ordinary non-one-piece molded round middle column. Obviously, the use of the round middle column has become a kind of technical prejudice or technical inertia. In addition, the exposure of copper wire is also a problem of traditional inductor devices, because it will lead to poor magnetic shielding effect, and the magnetic lines will be emitted to the surrounding environment, interfering with surrounding components.

[0006] To this end, we proposed an integrated molded inductor. Utility Model Content

[0007] The utility model provides an integrally formed inductor, which solves the problem mentioned in the background technology that the existing inductor adopts a non-integrated round center column, the copper wire is exposed, which easily leads to poor magnetic shielding effect, and the magnetic lines of force will be emitted to the surrounding environment, interfering with surrounding components.

[0008] The technical solution of the utility model is as follows:

[0009] An integrally formed inductor comprises a magnetic structure and a conductor coil, wherein the magnetic structure comprises a third magnet and a prefabricated first magnet, the conductor coil is wound around the outer surface of the magnetic structure, the third magnet is coated on the outer surfaces of the conductor coil and the magnetic structure, the conductor coil is not exposed, and the conductor coil is an integrally formed rectangular parallelepiped structure, the first magnet is a center column with a rectangular cross-section, and the conductor coil is a rectangular coil matched with the first magnet.

[0010] As a further technical solution of the utility model, the four corners of the rectangular cross-section of the first magnet are rounded, and the chamfer R is greater than 2 mm, and the conductor coil has a chamfer that matches the first magnet.

[0011] As a further technical solution of the utility model, the chamfer R is less than 5 mm.

[0012] As a further technical solution of the present invention, the distances from the circumferential surface of the first magnet to the circumferential surface of the corresponding third magnet are equal.

[0013] As a further technical solution of the utility model, one end of the first magnet is fixedly connected to a second magnet, and the second magnet is a magnet plate with a rectangular cross-section.

[0014] As a further technical solution of the utility model, the other end of the first magnet is fixedly connected to a second magnet.

[0015] As a further technical solution of the utility model, the third magnet is enclosed in the shell.

[0016] As a further technical solution of the utility model, the third magnet covers the winding part of the conductor coil inside the shell and the entire first magnet and the second magnet, and the density and magnetic performance of the first magnet are greater than those of the third magnet.

[0017] The working principle and beneficial effects of the utility model are:

[0018] 1. In the utility model, a first magnet is formed by a central column of a rectangular structure to obtain a larger effective core cross-sectional area (Ae), maximizing the use of space, thereby achieving the purpose of increasing inductance, reducing magnetic flux density and core loss, and the density and performance of the first magnet are much higher than the third magnet obtained by wrapping the coil and solidifying the magnetic slurry of the first magnet; the overall proportion is larger than that of a circular magnetic rod, so the performance obtained is better. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The utility model is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0020] Figure 1 is a schematic diagram of the three-dimensional structure of the inductor of Example 1;

[0021] Figure 2 is a schematic diagram of the three-dimensional structure of the first magnet in Example 1;

[0022] Figure 3 is a schematic diagram of a three-dimensional structure of an inductor according to Embodiment 2;

[0023] Figure 4 is a schematic diagram of the three-dimensional structure of the first magnet in Example 2;

[0024] Figure 5 is a schematic diagram of a three-dimensional structure of an inductor according to Embodiment 3;

[0025] Figure 6 is a schematic diagram of the three-dimensional structure of the first magnet in Example 3;

[0026] Figure 7 is a schematic diagram of the three-dimensional structure of the inductor of Comparative Example 4;

[0027] Figure 8 for Figure 7 Section intention in the AA direction;

[0028] Fig. 9 is a schematic diagram of a three-dimensional structure of an inductor according to Embodiment 5;

[0029] Fig.10 for Fig. 9 Section intention in the BB direction.

[0030] In the figure: 1. magnet structure; 2. conductor coil; 3. shell; 11. first magnet; 12. second magnet; 13. third magnet; 41. magnet No. 1; 42. magnet No. 2; 43. magnet No. 3; 5. existing coil. DETAILED DESCRIPTION

[0031] The following will be combined with the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model. Example 1

[0032] like Figure 1-2 As shown, this embodiment proposes an integrated inductor, including a magnetic structure 1, a conductor coil 2, and a housing 3 can also be added to further increase reliability and withstand voltage level;

[0033] The magnet structure 1 is in the shape of a cuboid or a cube as a whole, or at least the effective part is in the shape of a cuboid;

[0034] The magnet includes a first magnet 11 and a third magnet 13. The first magnet 11 is a rectangular parallelepiped magnetic column, and a rectangular conductor coil 2 is sleeved on the magnetic column;

[0035] The first magnet 11 is formed by pressing soft magnetic alloy powder, and the third magnet 13 is obtained by solidifying magnetic slurry; the density and performance of the first magnet 11 are much higher than the third magnet 13 obtained by solidifying the magnetic slurry that wraps the conductor coil 2 and the first magnet 11; the third magnet 13 wraps the first magnet 11 and the conductor coil 2 wound on the first magnet 11 to form a rectangular parallelepiped structure;

[0036] The four corners of the rectangular coil are all rounded (corner radius R4.5mm), which is convenient for winding processing and prevents the paint film at the four corners from being stretched too much during the winding process and causing rupture; the four corners of the first magnet 11 are also rounded accordingly, matching the rounded corners of the coil; the third magnet 13 is externally used with magnetic packaging material to wrap the first magnet 11 and the conductor coil 2 into a whole, forming a rectangular inductor element;

[0037] In this embodiment, the first magnet 11 is a magnetic column with a rectangular cross-section. Compared with a circular magnetic rod, it can achieve a larger effective core cross-sectional area (Ae), maximize the use of space, and thus achieve the purpose of increasing inductance and reducing flux density and core loss; it is covered with a high-temperature resistant shell to further improve the voltage resistance level. If the voltage resistance requirement in the use scenario is not particularly high, the high-temperature resistant shell can be omitted. Example 2

[0038] like Figure 3-4 As shown, different from the embodiment, a sheet magnet is added to one side of the first magnet 11 as the second magnet 12 , and the magnetic packaging material wrapped outside is used as the third magnet 13 .

[0039] In this embodiment, since the density and performance of the first and second magnets are higher than the magnetic packaging materials, and the second magnet 12 replaces part of the magnetic packaging materials, the structure can further increase the inductance of the inductor and reduce its overall loss. The high-density and high-performance magnets account for a larger proportion, thereby improving performance. A high-temperature resistant shell is added to further improve the withstand voltage level. If the withstand voltage requirements in the usage scenario are not particularly high, a high-temperature resistant shell may not be added. Example 3

[0040] like Figure 5-6 As shown, compared with Example 2, other structures remain unchanged, and a sheet magnet is added on both sides of the first magnet 11 as the second magnet 12, and the magnetic packaging material wrapped outside is used as the third magnet 13, so as to further improve the inductance of the inductor and reduce its overall loss; a high-temperature resistant shell is put on to further improve the withstand voltage level. If the withstand voltage requirement in the use scenario is not particularly high, the high-temperature resistant shell can be omitted.

[0041] The present invention includes a magnet structure 1 and a conductor coil 2, and a shell 3 can also be added to further increase reliability and withstand voltage level; the magnet includes a first magnet 11, a second magnet 12 and a third magnet 13; the first magnet 11 is a rectangular middle column, the second magnet 12 is the top plate at both ends of the middle column, the first magnet 11 and the second magnet 12 are matched with each other up and down, the conductor coil 2 is a rectangular coil wound on the rectangular first magnet 11 and the inner side of the second magnet 12, the third magnet 13 is a magnetic filling material, and the third magnet 13 fills the gap between the first and second magnets and the conductor coil 2; so that there is no insulating air gap between the magnets, and the reliability is high;

[0042] At the same time, since the magnetic center column and the conductor coil 2 are both rectangular, the space can be maximized and the effective core cross-sectional area Ae can be increased, so that the inductor has the characteristics of high inductance, high saturation and low core loss.

[0043] Since the conductor coil 2 is completely wrapped in the magnet, there is no magnetic leakage, magnetic shielding effect, and strong anti-interference ability; since the third magnet 13 wrapping the coil is a metal magnetic material, its thermal conductivity is significantly better than traditional thermal conductive glue, so the heat dissipation capacity is good; all components form a whole, so the reliability is high; there is no gap between the coil and the magnets, so no noise will be generated under high-frequency vibration.

[0044] In order to illustrate the technical effect of the present invention, the specific size parameters of the inductor used in this embodiment are provided:

[0045] The overall dimensions of the one-piece molded inductor are: length 44mm*width 36mm*height 27mm.

[0046] Comparative Example 4

[0047] like Figure 7-8 As shown, the diameter of the No. 1 magnet 41 of the circular magnetic bar is 14 mm, the height is 32.5 mm, and the size of the No. 2 magnet 42 is 32 mm long, 22 mm wide, and the thickness of the two top pieces is 4 mm; the magnetic permeability of the No. 1 and No. 2 magnets 42 is 60 μ;

[0048] The third magnet 43 is a solidified soft magnetic slurry that wraps the first and second magnets 42 and the existing coil 5 (3.2*0.6*40TS coil) to form an integral inductor. Example 4

[0049] like Figure 9-10 As shown, the first magnet 11 of the rectangular center column is 18 mm long, 14 mm wide and 32.5 mm high; the chamfer of the right angle side of the cylinder is a fillet of R3.5 mm, and the size of the second magnet 12 is two top sheets of 32 mm long, 22 mm wide and 4 mm thick;

[0050] The first and second magnets 12 have the same magnetic permeability of 60μ; the third magnet 13 is a solidified soft magnetic slurry that wraps the first and second magnets 12 and the conductor coil 2 (3.2*0.6*40TS) to form an integral inductor.

[0051] category Ae(CM²) L(μH) Bpk(Gs) Graphics Comparative Example 4 2.076 329 260 Figure 7-8 Example 5 3.439 435 157 Figure 9-10

[0052] The above table is a comparison diagram between comparative example 4 and embodiment 5, wherein Ae is the effective magnetic powder core cross-sectional area; L is the inductance; and Bpk is the maximum magnetic flux density peak value.

[0053] Magnetic flux density condition ( :(effective value of sinusoidal voltage through winding) 48v, f:(sinusoidal waveform voltage frequency) 50KHzN:(number of coil turns) 40Ts)

[0054] In summary, the rectangular center column first magnet 11 can obtain a larger effective core cross-sectional area (Ae), maximizing the use of space, thereby achieving the purpose of increasing inductance and reducing flux density and core loss; at the same time, because the first magnet 11 is formed by pressing soft magnetic alloy powder, the density and performance are much higher than the third magnet 13 obtained by solidifying the magnetic slurry of the wrapped coil and the first magnet 11; the overall proportion is larger than that of the circular magnetic rod, so the performance obtained is better.

[0055] In addition, small fillet coils are difficult to manufacture and cannot be mass-produced, and are prone to damage the insulation layer of the conductor coil 2, thereby increasing the risk of poor withstand voltage.

[0056] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An integrally formed inductor, comprising a magnetic structure (1) and a conductor coil (2), wherein the magnetic structure (1) comprises a third magnet (13) and a prefabricated first magnet (11), the conductor coil (2) is wound around the outer surface of the magnetic structure (1), the third magnet (13) is coated on the outer surfaces of the conductor coil (2) and the magnetic structure (1), the conductor coil (2) is not exposed, and the conductor coil (2) is an integrally formed rectangular parallelepiped structure, It is characterized in that The first magnet (11) is a center column with a rectangular cross-section, and the conductor coil (2) is a rectangular coil that matches the first magnet (11).

2. The one-piece molded inductor according to claim 1, It is characterized in that The four corners of the rectangular cross section of the first magnet (11) are rounded, and the chamfer R is greater than 2 mm, and the conductor coil (2) has a chamfer that matches the first magnet (11).

3. The one-piece molded inductor according to claim 2, It is characterized in that The chamfer R is less than 5mm.

4. The one-piece molded inductor according to any one of claims 1 to 3, It is characterized in that The distances from the circumference of the first magnet (11) to the outer circumference of the corresponding third magnet (13) are equal.

5. The one-piece molded inductor according to claim 4, It is characterized in that One end of the first magnet (11) is fixedly connected to a second magnet (12), and the second magnet (12) is a magnet plate with a rectangular cross-section.

6. The one-piece molded inductor according to claim 5, It is characterized in that The other end of the first magnet (11) is fixedly connected to a second magnet (12).

7. The one-piece molded inductor according to claim 6, It is characterized in that The third magnet (13) is enclosed in the housing (3).

8. The one-piece molded inductor according to claim 7, It is characterized in that The third magnet (13) covers the winding portion of the conductor coil (2) inside the housing (3) and the entire first magnet (11) and the second magnet (12), and the density and magnetic performance of the first magnet (11) are greater than those of the third magnet (13).

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