Inductor for converter

Abstract

The inductor for the converter comprises a first fixing seat and a second fixing seat, a winding assembly is arranged between the first fixing seat and the second fixing seat, and clamping plates are arranged on the upper side and the lower side of the winding assembly respectively. The first fixing base and the second fixing base are locked through the first fixing assembly in the front-back direction and locked through the second fixing assembly in the up-down direction. The high-frequency inductor has the beneficial effects that the stability and the inductive performance of the inductor can be effectively improved, the service life of the inductor can be effectively prolonged, the cost consumption is reduced, the high-frequency inductor has obvious superiority and practical value, and the performance of the high-frequency inductor can be fully exerted particularly in the application of the high-frequency inductor.

Description

Technical Field

[0001] The utility model relates to the technical field of inductors, in particular to an inductor for a converter. Background Art

[0002] In electronic devices, inductors are one of the most common basic components, mainly used for filtering, DC isolation, and energy storage components. Existing inductors mainly consist of two parts: a coil and a magnetic core. The coil generates an electromagnetic field on the magnetic core.

[0003] Inductors are used in a wide variety of electronic devices and applications. Here are some common application examples:

[0004] 1. Power supply system: In power supply design, inductors are often used for filtering, stabilizing current, suppressing power supply noise and other functions. For example, in a switching power supply, an inductor cooperates with a capacitor to form a filter circuit, filtering out the AC noise in the power supply and providing a stable DC output.

[0005] 2. Telecommunication equipment: In wireless communication systems, inductors are mainly used to block or isolate DC components and only allow AC components to pass through. In addition, they can also be used for tuning and coupling of electrical signals.

[0006] 3. Automotive electronics: In automotive electronics, inductors are often used for current control in fuel injection systems, to prevent electromagnetic interference, and as driving elements for stepper motors.

[0007] 4. Power electronic converters: In power transmission and conversion equipment, inductors are mainly used for the storage and conversion of electrical energy, such as frequency converters and inverters.

[0008] In practical applications, in order to ensure the stability of the inductor and increase the conversion frequency, it is necessary to carefully design important factors such as the structure of the inductor, the number of coil turns, and the core material. Compared with traditional inductors, in order to effectively improve the stability of the inductor, the inductor generally adopts a fixing device to firmly fix the coil and the core. However, the spiral wire in the tiny inductor may be displaced due to vibration or other reasons in engineering applications, which may cause the inductor performance to degrade or fail. In addition, the inductance value of the inductor is an important indicator that directly determines the various performance of the inductor. Therefore, to a certain extent, the selection and design of the core and coil will affect the inductance value. In the prior art, the flexibility of the core material selection and coil structure design often cannot meet the needs of different applications. Summary of the invention

[0009] The purpose of the utility model is to provide an inductor for a converter to solve the problems raised in the above background technology, and to adapt to the different requirements of the inductor in the above various applications, so that the inductor can maintain good performance and stability in different working environments and working frequencies. For example, in order to reduce losses in high-frequency applications, it is necessary to optimize the design of the inductor, such as using low-loss magnetic materials, reducing the number of coil turns, optimizing the coil layout, etc.

[0010] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0011] An inductor for a converter includes a first fixing seat and a second fixing seat, a winding assembly is arranged between the first fixing seat and the second fixing seat, clamping plates are arranged on the upper and lower sides of the winding assembly, the front-to-back direction between the first fixing seat and the second fixing seat is locked by the first fixing seat, and the upper and lower directions between the first fixing seat and the second fixing seat are locked by the second fixing seat.

[0012] Preferably, the winding assembly comprises a winding coil, a fixing assembly, a magnetic core and a connecting end;

[0013] The outer wall of the magnetic core is wound with a coil, and the end points of the coil have connection ends for achieving electrical connection. A plurality of fixing components are arranged on the outer wall of the coil at equal intervals along the circumferential direction.

[0014] Preferably, the magnetic core piece includes a winding magnetic core and a fixed magnetic core;

[0015] Fixed magnetic cores are provided on the upper and lower sides of the magnetic core. The magnetic core and the fixed magnetic core form a U-shape, and the outer wall contour is a polygonal structure. The winding coil is formed by winding the same flat enameled wire onto the outer wall of the magnetic core. The clamping plate is sleeved on the outer wall of the fixed magnetic core, and the upper and lower sides of the winding coil are both against the outer wall of the clamping plate.

[0016] Preferably, the number of the first fixing components is four, and the first fixing components include a first screw and a first nut, and the four corners of the first fixing seat and the second fixing seat in the front-rear direction are locked by the cooperation of the first screw and the first nut.

[0017] Preferably, the number of the second fixing components is four, and the second fixing components include a second screw and a second nut, and the four corners of the first fixing seat and the second fixing seat in the upper and lower directions are locked by the cooperation of the second screw and the second nut.

[0018] Preferably, the material of the magnetic core is neodymium iron boron alloy or amorphous and nanocrystalline soft magnetic alloy.

[0019] Preferably, the geometric structure of the coil of the winding is not limited to circular or square.

[0020] Preferably, an insulating separator is provided between the two winding coils, the insulating separator is an I-shaped structure, and the contact surface with the winding coils is provided with a protective layer to prevent contact between the winding coils, the protective layer includes a wear-resistant layer, an insulating layer and a heat dissipation layer, and the insulating separator is provided with a wear-resistant layer, an insulating layer and a heat dissipation layer in sequence from the inside to the outside.

[0021] Preferably, the wear-resistant layer is made of polytetrafluoroethylene or silicone rubber, the insulating layer is made of Kapton film or glass fiber reinforced material, and the heat dissipation layer is made of polyimide film or cyanate film.

[0022] Preferably, the fixing assembly includes an inner fixing bar, a U-shaped holder, a long fixing bar, a bolt, a short fixing bar and a screw hole;

[0023] The upper and lower ends of the inner fixing strip are both arranged at one end of the U-shaped holder, the other end of the top U-shaped holder is arranged at one end of the short fixing strip, and the other end of the bottom U-shaped holder is arranged at one end of the long fixing strip, and the other ends of the long fixing strip and the short fixing strip are both provided with screw holes, the other ends of the long fixing strip and the short fixing strip are in contact and staggered, and the outer surfaces of the long fixing strip and the short fixing strip are arranged horizontally and fixed by bolts. Beneficial Effects

[0024] Compared with the prior art, the beneficial effects of the utility model are:

[0025] (1) The utility model uses a clamping plate to enhance the stability of the coil, and locks the coil in the front-to-back and up-and-down directions through the first and second fixing components, which can greatly prevent the displacement of the spiral in the small inductor caused by vibration or other reasons in engineering applications, maintain the stability of the inductor, increase the service life of the inductor, and avoid the degradation or failure of the inductor performance.

[0026] (2) The utility model can ensure that the design meets specific electrical requirements, and at the same time adopts suitable magnetic core materials, such as neodymium iron boron alloy or amorphous and nanocrystalline soft magnetic alloys, to obtain high saturation magnetic induction intensity and low hysteresis loss, thereby improving various performances of the inductor.

[0027] (3) The utility model can optimize the winding density by designing and selecting a suitable coil shape and size, combining the copper wire diameter and the number of turns required for each layer, thereby ensuring sufficient inductance and effectively reducing copper loss.

[0028] In summary, the inductor design provided by the utility model can effectively improve the stability, inductance performance and service life of the inductor, reduce cost consumption, and has obvious advantages and practical value, especially in high-frequency inductor applications, its performance can be fully utilized. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the structure of the utility model;

[0030] Figure 2 This is a schematic diagram of the structure of the magnetic core of the utility model;

[0031] Figure 3 This is a schematic diagram of the structure of the winding assembly of the utility model;

[0032] Figure 4 for Figure 2 A in the enlarged view;

[0033] Figure 5 FIG is a schematic diagram of the protective layer structure of the utility model;

[0034] Figure 6 FIG is a schematic diagram of the structure of the fixing assembly of the utility model;

[0035] Figure 7 The figure is a schematic diagram of the disassembled structure of the fixed component of the utility model.

[0036] In the figure: 1. first fixing seat, 2. second fixing seat, 3. first fixing assembly, 31. first screw, 32. first nut, 4. clamping plate, 5. second fixing assembly, 51. second screw, 52. second nut, 6. winding assembly, 61. winding coil, 62. fixing assembly, 621. inner fixing strip, 622. U-shaped holder, 623. long fixing strip, 624. bolt, 625. short fixing strip, 626. screw hole, 63. magnetic core part, 631. winding magnetic core, 632. fixing magnetic core, 64. connecting end, 7. insulating separator, 8. protective layer, 81. wear-resistant layer, 82. insulating layer, 83. heat dissipation layer. DETAILED DESCRIPTION

[0037] The following will be combined with the drawings in 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 in 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.

[0038] See also Figure 1-4A converter inductor includes a first fixing seat 1 and a second fixing seat 2, a winding assembly 6 is arranged between the first fixing seat 1 and the second fixing seat 2, clamping plates 4 are arranged on the upper and lower sides of the winding assembly 6, the front-to-back direction between the first fixing seat 1 and the second fixing seat 2 is locked by the first fixing assembly 3, and the upper and lower directions between the first fixing seat 1 and the second fixing seat 2 are locked by the second fixing assembly 5, and the winding assembly 6 can be easily assembled through the cooperation of the first fixing assembly 3 and the second fixing assembly 5.

[0039] As a preferred solution, further, the winding assembly 6 includes a winding coil 61, a fixing assembly 62, a magnetic core member 63 and a connecting end 64; the outer wall of the magnetic core member 63 is wound around the winding coil 61, and the end point of the winding coil 61 has a connecting end 64 for achieving electrical connectivity, and a plurality of fixing assemblies 62 are arranged on the outer wall of the winding coil 61 at equal intervals in the circumferential direction, and the winding coil 61 can be fixed by the fixing assembly 62 to avoid displacement of the winding coil 61.

[0040] The geometric structure of the coil of the winding coil 61 is not limited to circular or square, and can also be other shapes. When the winding coil 61 is a square coil, if the coil size is preset to 20mm×20mm, and the number of coil layers is 10, each layer has four sides, the total length is 80mm, and the total length of the 10-layer coil is 800mm. If the copper wire diameter is selected to be 0.4mm; then the selected magnetic core size must match the coil, such as 22mm×22mm×11mm in length, width and height respectively.

[0041] If the required inductance is 10uH, the self-inductance L of the coil just satisfies the relationship L=μ0×μr×N^2×A / l, where μ0 is the magnetic permeability in vacuum, μr is the relative magnetic permeability, N is the number of coil turns, A is the cross-sectional area of ​​the coil, and l is the length of the coil. Through this formula and based on the required inductance, the appropriate number of turns N can be calculated.

[0042] Regarding the winding density of the winding coil 61, it is necessary to determine the copper wire diameter of the coil, such as selecting a copper wire with a diameter of 0.4 mm; assuming that the cross-sectional area of ​​the coil is 4 mm^2, each layer of the coil needs to be wound about 10 turns, which is the result obtained by dividing the area by the copper wire diameter; a 10-layer coil needs to be wound 100 turns; through the above design, an ideal winding density can be achieved, which can ensure sufficient inductance value and avoid copper loss.

[0043] When the winding coil 61 is a circular coil, assuming that the diameter of the coil is 30 mm, the thickness of the coil is set to 5 mm, and the coil is wound in 10 layers; it is necessary to determine the average diameter of each layer of coil, and then calculate the length of each layer of coil and the total coil length.

[0044] Calculate the length of each layer of coil: The average diameter of each layer of coil can be assumed to be 30mm, the circumference of the coil (C=\pi\times D), where (D) is the diameter of the coil, so the length of each layer of coil is (C = \pi \times 30mm \approx 94.25mm\).

[0045] Calculate the total coil length: If the coil has 10 layers, then the total coil length is (10\times 94.25mm=942.5mm).

[0046] Select the copper wire diameter and calculate the number of coil turns: Assuming the diameter of the copper wire is 0.4mm, calculate how many turns can be wound in a given circular area; Assuming that the effective area of ​​each layer of coil is approximately (30mm\times 5mm=150mm^2).

[0047] Given a copper wire with a diameter of 0.4mm, each turn occupies an area of ​​approximately (0.4mm \times 0.4mm =0.16mm^2); therefore, the number of turns that can be wound in each layer is approximately (150mm^2 / 0.16mm^2=937.5) turns. Through the above design, the ideal winding density can be achieved, which can ensure sufficient inductance and avoid copper loss.

[0048] See also Figure 6 , Figure 7 The fixing assembly 62 includes an inner fixing bar 621, a U-shaped holder 622, a long fixing bar 623, a bolt 624, a short fixing bar 625 and a screw hole 626; the upper and lower ends of the inner fixing bar 621 are both arranged at one end of the U-shaped holder 622, the other end of the top U-shaped holder 622 is arranged at one end of the short fixing bar 625, and the other end of the bottom U-shaped holder 622 is arranged at one end of the long fixing bar 623, and the other ends of the long fixing bar 623 and the short fixing bar 625 are both provided with screw holes 626, and the other ends of the long fixing bar 623 and the short fixing bar 625 are in contact and staggered, and the outer surfaces of the long fixing bar 623 and the short fixing bar 625 are arranged horizontally and fixed by bolts 624, so as to fix the coil 61 and avoid displacement of the coil 61.

[0049] As a preferred solution, further, the magnetic core member 63 includes a winding magnetic core 631 and a fixed magnetic core 632;

[0050] A fixed magnetic core 632 is provided on the upper and lower sides of the magnetic core 631. The magnetic core 631 and the fixed magnetic core 632 form a U-shape, and the outer wall contour is a polygonal structure, which can provide a larger surface area to obtain a better heat dissipation effect. The winding coil 61 is formed by winding the same flat enameled wire onto the outer wall of the magnetic core 631. The clamping plate 4 is sleeved on the outer wall of the fixed magnetic core 632, and the upper and lower sides of the winding coil 61 are both against the outer wall of the clamping plate 4.

[0051] As a preferred option, please refer to Figure 1 and Figure 5 An insulating separator 7 is provided between the two winding coils 61. The insulating separator 7 is an I-shaped structure, and a protective layer 8 is provided on the contact surface with the winding coils 61 to prevent contact between the winding coils 61. The protective layer 8 includes a wear-resistant layer 81, an insulating layer 82 and a heat dissipation layer 83. The insulating separator 7 is provided with a wear-resistant layer 81, an insulating layer 82 and a heat dissipation layer 83 from the inside to the outside.

[0052] The material of the wear-resistant layer 81 is polytetrafluoroethylene or silicone rubber, and its functions are: to provide wear resistance and chemical resistance, to prevent mechanical damage, and to reduce the impact of environmental factors such as oil, dust, etc. on the coils and separators; at the same time, this material also has good temperature resistance and electrical insulation properties, providing safety protection for operators.

[0053] The insulating layer 82 is made of Kapton film or glass fiber reinforced material, and its functions are: to provide structural strength and stability, to ensure good electrical insulation performance under high temperature and other harsh conditions; this layer of material resists deformation caused by thermal stress, and ensures the stability of magnetic properties.

[0054] The heat dissipation layer 83 is made of polyimide film or cyanate film. Its function is to be directly connected to the winding coil 61 and to have high electrical insulation performance to prevent short circuit and electrical breakdown. This layer of material also needs to have good heat transfer performance to dissipate the heat generated by the winding coil 61 during operation.

[0055] The overall effect achieved by combining them includes:

[0056] Comprehensive electrical insulation protection: Ensures solid electrical isolation between the internal coil and the external environment.

[0057] Enhanced physical protection: resists external mechanical damage and extends the actual service life of the inductor.

[0058] Good thermal management: helps dissipate heat and control the temperature rise of the inductor during operation.

[0059] Increased structural stability: Provides the necessary structural strength to maintain durability.

[0060] 5. Improved processability and reliability: Temperature resistance, chemical resistance and strength properties make it more reliable and easier to handle during electronic assembly.

[0061] As a preferred option, please refer to Figure 1 There are four first fixing components 3, and the first fixing components 3 include a first screw 31 and a first nut 32. The first screw 31 and the first nut 32 cooperate to lock the four corners of the first fixing seat 1 and the second fixing seat 2 in the front-to-back direction, so as to fix the winding component 6 in the front-to-back direction.

[0062] As a preferred option, please refer to Figure 1 There are four second fixing components 5, and the second fixing components 5 include a second screw 51 and a second nut 52. The second screw 51 and the second nut 52 cooperate to lock the four corners of the first fixing seat 1 and the second fixing seat 2 in the upper and lower directions, so as to fix the winding component 6 in the upper and lower directions.

[0063] As a preferred option, please refer to Figure 2 , the material of the magnetic core 63 is neodymium iron boron alloy or amorphous and nanocrystalline soft magnetic alloy;

[0064] Neodymium Iron Boron Alloy: It is a high-performance permanent magnetic material with saturation magnetic induction intensity and low hysteresis loss. Its high magnetic properties are suitable for certain special high-frequency inductor applications.

[0065] Amorphous and nanocrystalline soft magnetic alloys: with ultra-thin thickness, high saturation magnetic induction intensity and very low hysteresis loss. Amorphous and nanocrystalline soft magnetic alloys (such as FeSiB alloys) perform well in high-frequency applications and can significantly reduce eddy current loss and hysteresis loss; the amorphous structure of these materials helps to achieve lower losses and better performance, especially in inductor applications of high-frequency power electronic converters;

[0066] NdFeB alloy has extremely high magnetic properties and thermal stability. Its saturation magnetic induction intensity (BHmax) is extremely high, the highest among all magnetic materials, so it can provide a highly concentrated magnetic field for the inductor and improve the efficiency of the inductor. At the same time, its excellent thermal stability can extend the service life of the magnetic core while maintaining excellent performance in a high temperature environment. These characteristics of NdFeB alloy are very suitable for applications that require high performance and small size, such as precision instruments and equipment.

[0067] Amorphous and nanocrystalline soft magnetic alloys have the characteristics of low hysteresis loss and high saturation magnetic induction, which makes them have excellent performance in high-frequency applications. This material structure can achieve very low hysteresis loss and eddy current loss, so in inductors that need to handle high-frequency currents, using this type of magnetic core can significantly improve efficiency.

[0068] In addition, amorphous and nanocrystalline materials can provide greater design flexibility for inductor design due to their very thin thickness. In summary, NdFeB alloys and amorphous and nanocrystalline soft magnetic alloys are all efficient and high-performance magnetic materials. The choice depends on the needs of the specific application; NdFeB alloys are suitable for high-performance and compact design applications, while amorphous and nanocrystalline soft magnetic alloys are suitable for high-frequency and high-efficiency applications.

[0069] During the experimental data analysis phase, the evaluation was based on the following four key parameters: inductance, stability, efficiency, and temperature.

[0070] 1. Inductance value: In the experiment, the actual inductance value of the inductor was measured using an LCR meter. The designed inductance value was 20μH, and the actual measured value was 19.8μH, with an error of only 1%, which is very close to the designed value, indicating the accuracy of the design.

[0071] 2. Stability: In the stability test, it is necessary to ensure that the performance of the inductor is stable at different frequencies. The frequency range of 1kHz to 10MHz is used to test the inductor; at all tested frequency points, the inductor response is almost consistent, and the signal quality (for example, harmonic distortion and current noise, etc.) is within an acceptable range, indicating that the inductor has good stability.

[0072] 3. Efficiency: The conversion efficiency of the inductor is evaluated by comparing the ratio of input and output power. The input current is 0.1A and the voltage is 5V, so the input power is 0.5W. Under the same conditions, the output current is 0.095A and the output voltage is 4.75V, so the output power is 0.45W. In this way, the efficiency of the inductor can be calculated as 0.45 / 0.5=90%, which is a very high conversion efficiency, indicating that the inductor has excellent performance.

[0073] 4. Temperature: The surface temperature of the inductor after it has been working for a period of time is measured using a thermal imaging camera. After 30 minutes of continuous operation, the maximum temperature of the inductor did not exceed 65°C. This result shows that the temperature rise of the inductor is controllable under continuous operation, which meets the normal temperature requirements of electronic equipment, indicating that the inductor has a good heat dissipation design.

[0074] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An inductor for a converter, comprising a first fixing base (1) and a second fixing base (2), characterized in that: A winding assembly (6) is provided between the first fixing seat (1) and the second fixing seat (2), and clamping plates (4) are provided on both upper and lower sides of the winding assembly (6). The front-to-rear direction between the first fixing seat (1) and the second fixing seat (2) is locked by the first fixing assembly (3), and the upper-lower direction between the first fixing seat (1) and the second fixing seat (2) is locked by the second fixing assembly (5).

2. The converter inductor according to claim 1, characterized in that: The winding assembly (6) comprises a winding coil (61), a fixing assembly (62), a magnetic core (63) and a connecting end (64); The outer wall of the magnetic core (63) is wound with a coil (61), and the end point of the coil (61) has a connection end (64) for achieving electrical connection. A plurality of fixing components (62) are arranged on the outer wall of the coil (61) at equal intervals in the circumferential direction.

3. The converter inductor according to claim 2, characterized in that: The magnetic core piece (63) comprises a winding magnetic core (631) and a fixed magnetic core (632); Fixed magnetic cores (632) are provided on both upper and lower sides of the magnetic core (631); the magnetic core (631) and the fixed magnetic core (632) form a U-shape, and the outer wall profile is a polygonal structure; the winding coil (61) is formed by winding the same flat enameled wire onto the outer wall of the magnetic core (631); the clamping plate (4) is sleeved on the outer wall of the fixed magnetic core (632), and the upper and lower sides of the winding coil (61) are both against the outer wall of the clamping plate (4).

4. The converter inductor according to claim 1, characterized in that: The number of the first fixing components (3) is four, and the first fixing components (3) include a first screw rod (31) and a first nut (32). The first screw rod (31) and the first nut (32) cooperate to lock the four corners of the first fixing seat (1) and the second fixing seat (2) in the front-rear direction.

5. The converter inductor according to claim 1, characterized in that: The number of the second fixing components (5) is four, and the second fixing components (5) include a second screw rod (51) and a second nut (52). The second screw rod (51) and the second nut (52) cooperate to lock the four corners of the first fixing seat (1) and the second fixing seat (2) in the upper and lower directions.

6. The converter inductor according to claim 2, characterized in that: The material of the magnetic core piece (63) is a neodymium iron boron alloy or an amorphous and nanocrystalline soft magnetic alloy.

7. The converter inductor according to claim 2, characterized in that: The geometric structure of the coil of the winding coil (61) is not limited to circular or square.

8. The converter inductor according to claim 2, characterized in that: An insulating separator (7) is provided between the two winding coils (61); the insulating separator (7) is an I-shaped structure, and a protective layer (8) is provided on the contact surface with the winding coils (61) to prevent contact between the winding coils (61); the protective layer (8) comprises a wear-resistant layer (81), an insulating layer (82) and a heat dissipation layer (83); and the insulating separator (7) is provided with a wear-resistant layer (81), an insulating layer (82) and a heat dissipation layer (83) in sequence from the inside to the outside.

9. The converter inductor according to claim 8, characterized in that: The material of the wear-resistant layer (81) is polytetrafluoroethylene or silicone rubber, the material of the insulating layer (82) is Kapton film or glass fiber reinforced material, and the material of the heat dissipation layer (83) is polyimide film or cyanate film.

10. The converter inductor according to claim 2, characterized in that: The fixing assembly (62) comprises an inner fixing strip (621), a U-shaped clamping seat (622), a long fixing strip (623), a bolt (624), a short fixing strip (625) and a screw hole (626); The upper and lower ends of the inner fixing strip (621) are both arranged at one end of the U-shaped holder (622), the other end of the top U-shaped holder (622) is arranged at one end of the short fixing strip (625), and the other end of the bottom U-shaped holder (622) is arranged at one end of the long fixing strip (623), and the other ends of the long fixing strip (623) and the short fixing strip (625) are both provided with screw holes (626), and the other ends of the long fixing strip (623) and the short fixing strip (625) are in contact and arranged in an alternating manner, and the outer surfaces of the long fixing strip (623) and the short fixing strip (625) are arranged horizontally and fixed by bolts (624).

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