Vehicle-mounted boost inductor structure

Abstract

The utility model relates to an inductor structure. A vehicle-mounted boost inductor structure comprises a framework, a coil and at least three magnetic core blocks, an air gap is formed between every two adjacent magnetic core blocks, and a ceramic piece is installed in each air gap. The coil is wound on the prefabricated framework, a gap is formed between the prefabricated framework and the magnetic core block support, and the coil and the magnetic core block are assembled and then are subjected to injection molding to form an integrated framework. The utility model provides a vehicle-mounted boost inductor structure which is high in heat conduction efficiency, good in heat dissipation and high in inductor reliability. The technical problem that in the prior art, under the high-voltage current condition, heating of a boost inductor is high, and the reliability of a circuit is affected is solved.

Description

Technical Field

[0001] The utility model relates to an inductor structure, in particular to a vehicle-mounted boost inductor structure. Background Art

[0002] A boost inductor is an electronic component that can boost the power supply voltage. Its working principle is based on the principle of electromagnetic induction. The inductor generates a magnetic field by passing an alternating current through its coil. When the current is suddenly reduced or interrupted, the magnetic field collapses, generating a reverse electromotive force, causing the voltage in the inductor to rise rapidly.

[0003] The boost inductor plays the role of a gearbox in the car and has two main functions. First, it can change the direction of the current to achieve forward and reverse movement of the vehicle. Second, it increases the output current through electronic control to accelerate the drive motor. However, in this process, as the voltage increases, a lot of heat is generated. In a high temperature environment, magnetic components are prone to lose magnetism, which is an important issue. Generally, under high voltage current conditions, the inductor is very easy to lose heat, which affects the high reliability and safety of the circuit. Summary of the invention

[0004] The utility model provides a vehicle-mounted boost inductor structure with high heat conduction efficiency, good heat dissipation and high inductor reliability, and solves the technical problem in the prior art that the boost inductor generates high heat and affects circuit reliability under high voltage current conditions.

[0005] The above technical problems of the utility model are solved by the following technical solutions: a boost inductor structure for vehicle, comprising a skeleton, a coil and a core block, wherein the core block comprises at least 3 blocks, an air gap is formed between adjacent core blocks, and a ceramic sheet is installed in the air gap; the coil is wound on a prefabricated skeleton, and there is a gap between the prefabricated skeleton and the core block bracket, and the coil and the core block are assembled and injection molded into an integrated skeleton. Multiple air gaps are formed between multiple cores, and the inductor core adopts a multi-air gap structure, and a ceramic sheet with good thermal conductivity is used as an air gap between the cores. On the one hand, it has good thermal conductivity, which is conducive to the heat dissipation between the cores. It can allow a larger current to pass through, and can meet the requirements of high voltage and large current on the vehicle. Improve the reliability and safety of the circuit. In terms of process, the injection molding method is adopted, and the pressure resistance stability between the core and the coil is high, and a dense filling degree can be achieved. It can have better electromagnetic performance under the same design volume conditions. The boost inductor has the advantages of small size, stable structure and high reliability.

[0006] Preferably, the magnetic core block comprises U-shaped magnetic core blocks at both ends, a straight magnetic core block is located between the two U-shaped magnetic core blocks, and adjacent magnetic core blocks are fixed by glue. The magnetic cores at both ends adopt a U-shaped structure, which can reduce the length of the magnetic path and increase the inductance value.

[0007] Preferably, the ceramic sheet is a silicon oxide ceramic sheet, whose thermal conductivity (180w / m*k) is much higher than that of potting magnetic glue or thermosetting potting resin (2-10w / m*k), and can increase the heat conduction rate more effectively.

[0008] Preferably, the front and rear surfaces of the magnetic core block are provided with grooves. The purpose is to make the glue filling more dense and saturated, and further reduce the heat generation of the magnetic core. The increase in specific surface area is also conducive to heat dissipation. It can also reduce the injection pressure.

[0009] Preferably, the coil is wound with a flat wire, and the cross section of the flat wire is a trapezoid. The flat wire has a paint film structure with good insulation performance and good tensile resistance. The interface of the flat wire is a trapezoidal structure. When wound into a rectangular structure, the wire arrangement is more compact, and the risk of paint film damage at the bend is low, and a structure with a smaller R angle can be wound.

[0010] Preferably, the magnetic core formed by the magnetic core block is O-shaped, and two sets of coils are wound on the magnetic core. The two sets of coils are connected in series through a copper bar, and the copper bar and the coils are welded by argon arc. The joint welding is full and firm, and no obvious oxidation and blackening is observed at the copper wire welding point by argon arc welding.

[0011] Preferably, the magnetic core block is pressed from low-loss iron silicon powder, sendust powder or carbonyl iron powder or a mixture of several of them.

[0012] Therefore, the boost inductor structure for vehicle use of the utility model has the following advantages: the multi-air gap structure is realized by injection molding, and the multi-air gap structure is filled with silicon oxide ceramic sheets, which has good thermal conductivity, is conducive to the heat dissipation of the magnetic core, improves the stability of the boost inductor, and can also allow a larger current to pass through, meeting the current vehicle-mounted 800V high voltage and high current requirements. The slots on the magnetic core are conducive to the filling of glue and resin, and also increase the heat dissipation area. The flat coil wire has a low risk of paint film damage at the bend, and a structure with a smaller R angle can be wound to improve the inductor performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a three-dimensional diagram of the structure of a boost inductor for automotive use.

[0014] Figure 2 yes Figure 1 Front view of the magnetic core and silicon oxide ceramic sheet.

[0015] Figure 3 yes Figure 2 Plus a stereogram of the prefabricated skeleton.

[0016] Figure 4 yes Figure 3 Plus a stereogram of the coil. DETAILED DESCRIPTION

[0017] The technical solution of the utility model is further specifically described below through embodiments and in conjunction with the accompanying drawings.

[0018] Example:

[0019] like Figure 1 and 2 As shown in Figures 3 and 4, a boost inductor structure for vehicle use includes a magnetic core block 9 and a coil 3. The coil 3 is wound on a prefabricated skeleton 10, and the prefabricated skeleton 10 includes a frame-shaped frame, and the coil 3 is wound on the upper and lower groups of prefabricated skeletons 10. The coil 3 includes two groups parallel to each other, and the two groups of coils 3 are connected in series through a copper bar 4, and the copper bar 4 and the coil 3 are welded by argon arc. The coil 3 is wound by a flat wire, and the cross-section of the flat wire is trapezoidal. When winding, the coil structure is more compact, and the risk of paint film damage at the bend is small.

[0020] The magnetic core block 9 is O-shaped. The magnetic core block is pressed by low-loss iron silicon powder, iron silicon aluminum powder or carbonyl iron powder or a mixture of several of them. The magnetic core block 9 is composed of U-shaped magnetic cores 5 at both ends and two vertical magnetic cores 8. The two sets of coils are respectively located outside the two vertical magnetic cores 8 and are parallel to each other. An air gap is provided between two adjacent magnetic cores, and the air gap is filled with silicon oxide ceramic sheets 6. The silicon oxide ceramic sheets 6 are bonded to the surface of the magnetic core by glue. Vertical slots 7 are provided on the front and rear surfaces of the magnetic core. The slots 7 can facilitate the filling of glue and increase the heat dissipation area of ​​the magnetic core. After the magnetic core and the coil wound on the prefabricated skeleton are assembled, the two are fixed by injection molding to form a skeleton 1. At the same time, the nut 2 is installed during injection molding. After cooling and drying, the NTC sensor 11 is installed to complete the manufacture of the boost inductor.

[0021] The specific embodiments described herein are merely examples of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A boost inductor structure for vehicle use, comprising a skeleton, a coil and a magnetic core block, characterized in that: The magnetic core blocks include at least three blocks, an air gap is formed between adjacent magnetic core blocks, and a ceramic sheet is installed in the air gap; the coil is wound on the prefabricated frame, there is a gap between the prefabricated frame and the magnetic core block bracket, and the coil and the magnetic core block are assembled and injection molded into an integrated frame.

2. The vehicle-mounted boost inductor structure according to claim 1, characterized in that: The magnetic core block comprises U-shaped magnetic core blocks at both ends, a straight magnetic core block is located between the two U-shaped magnetic core blocks, and adjacent magnetic core blocks are fixed by glue.

3. A vehicle-mounted boost inductor structure according to claim 1 or 2, characterized in that: The ceramic sheet is a silicon oxide ceramic sheet.

4. A vehicle-mounted boost inductor structure according to claim 1 or 2, characterized in that: The front and rear surfaces of the magnetic core block are provided with slots.

5. The vehicle-mounted boost inductor structure according to claim 1 or 2, characterized in that: The coil is wound with a flat wire, and the cross section of the flat wire is trapezoidal.

6. A vehicle-mounted boost inductor structure according to claim 1 or 2, characterized in that: The magnetic core formed by the magnetic core block is O-shaped, and two groups of coils are wound on the magnetic core. The two groups of coils are connected in series through a copper bar, and the copper bar and the coils are welded by argon arc.

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