PFC inductor

Abstract

The utility model discloses a PFC (power factor correction) inductor which comprises an inductor body, the inductor body comprises a vertical magnetic ring, a first winding and a second winding, and the first winding is wound to the top of the vertical magnetic ring leftwards and upwards along the bottom of the vertical magnetic ring and then wound to the bottom of the vertical magnetic ring leftwards and downwards; the second winding is wound rightwards and upwards to the top of the vertical magnetic ring along the bottom of the vertical magnetic ring and then is wound rightwards and downwards to the bottom of the vertical magnetic ring; a top non-winding area is reserved at the top of the vertical magnetic ring; the outer ring peripheral side of the inductor main body is coated with an insulating tape; the copper foil is arranged along the peripheral side of the outer ring of the inductor body in a wrapping mode, and the copper foil is fixedly bonded with the non-winding areas of the bottom and the top of the inductor body respectively, so that gaps are correspondingly formed between the left side area and the right side area of the copper foil and between the left side area and the right side area of the inductor body. Therefore, the occupied space is reduced, the product height is reduced, the left side and the right side of the copper foil are naturally bent to form gaps with the outside of the winding, and heat dissipation of the winding is facilitated.

Description

Technical Field

[0001] The utility model relates to the technology of the inductor field, in particular to a PFC inductor. Background Art

[0002] Currently, PFC inductors are generally of single design. If two are required, for PFC inductor products with a magnetic ring structure, the magnetic rings are arranged side by side front to back, and wires are wound around each magnetic ring to form a corresponding winding, which is actually equivalent to arranging two PFC inductors side by side front to back. For PFC inductors with a magnetic column structure, they can be arranged side by side left to right or side by side front to back, which is actually equivalent to arranging two PFC inductors with a magnetic column structure together. Therefore, there are problems such as the overall large footprint.

[0003] For example, CN 114360862 A discloses a dual-path PFC inductor, comprising a magnetic core formed by a symmetrical combination of two bases, a skeleton embedded on the magnetic core and a twisted coil, wherein the twisted coil is wound on the skeleton; the base is provided with a first main core portion and a second main core portion from left to right, the first main core portion and the second main core portion are both circular, the base is provided with a first side wing portion and a second side wing portion on both sides, a third side wing portion is provided between the first main core portion and the second main core portion, an open groove is formed between the first side wing portion, the second side wing portion and the third side wing portion, a magnetic column and an epoxy plate gasket are provided in the skeleton from top to bottom, and an epoxy bottom plate is provided at the bottom of the base located below. This structure, on the one hand, has the above-mentioned problem of large overall space occupation, and on the other hand, the heat generated by the inductor when working is not easy to dissipate. For the case where the space reserved for the inductor layout on the product using the inductor is small, these two disadvantages are more obvious.

[0004] Therefore, it is necessary to study a new technical solution to solve the above problems. Utility Model Content

[0005] In view of this, the utility model aims to solve the deficiencies in the prior art, and its main purpose is to provide a PFC inductor, which integrates two windings on the same vertical magnetic ring. Compared with two PFC inductors, the overall occupied space is reduced, and in particular, the two windings are cleverly arranged to further reduce the product height. The natural bending of the left and right sides of the copper foil will form a gap with the outside of the winding, which is convenient for the heat dissipation of the winding.

[0006] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0007] A PFC inductor, comprising:

[0008] An inductor body, the inductor body comprising a vertical magnetic ring, a first winding and a second winding, the inner ring hole of the vertical magnetic ring is axially extended in the front-to-back direction; the first winding is wound upward to the left along the bottom of the vertical magnetic ring to the top of the vertical magnetic ring, and then wound downward to the left to the bottom of the vertical magnetic ring; the second winding is wound upward to the right along the bottom of the vertical magnetic ring to the top of the vertical magnetic ring, and then wound downward to the right to the bottom of the vertical magnetic ring; and a top non-winding area is reserved at the top of the vertical magnetic ring, so that the first winding and the second winding are respectively located on the left and right sides of the top non-winding area; the outer ring circumference of the inductor body is covered with insulating tape;

[0009] The copper foil is wrapped around the outer circumference of the inductor body, and the copper foil is bonded and fixed to the bottom and top non-winding areas of the inductor body respectively, so that the left and right areas of the copper foil and the left and right areas of the inductor body form gaps respectively.

[0010] As a preferred solution, it also includes an insulating substrate;

[0011] The insulating substrate is horizontally extended, and a first pin through hole, a second pin through hole, a third pin through hole and a fourth pin through hole are provided on the insulating substrate, the first pin through hole and the fourth pin through hole are located in the front end area of ​​the insulating substrate, and the second pin through hole and the third pin through hole are located in the rear end area of ​​the insulating substrate;

[0012] The first winding has a first pin and a second pin located at the bottom of the vertical magnetic ring, and the second winding has a third pin and a fourth pin located at the bottom of the vertical magnetic ring; the inductor body wrapped with the copper foil is located on the insulating substrate, and the first pin, the second pin, the third pin, and the fourth pin pass through the corresponding first pin through hole, the second pin through hole, the third pin through hole, and the fourth pin through hole.

[0013] As a preferred solution, the copper foil is formed into an elliptical shape by band-shaped enclosure and bonding, and the bonding part of the copper foil is located above the bottom of the vertical magnetic ring and maintains a vertical spacing with the insulating substrate.

[0014] As a preferred solution, an external lead is connected to the copper foil, and a welding point between the external lead and the copper foil is located above the bottom of the vertical magnetic ring and maintains a vertical spacing with the insulating substrate.

[0015] As a preferred solution, the welding point between the external lead and the copper foil and the joining point of the copper foil are respectively located on the left and right sides of the inductor body.

[0016] As a preferred solution, a bottom non-winding area is reserved at the bottom of the vertical magnetic ring, so that the first winding and the second winding are respectively located on the left and right sides of the bottom non-winding area, and the copper foil is bonded and fixed to the bottom non-winding area.

[0017] As a preferred solution, a deposition groove is provided on the insulating substrate, and the deposition groove passes through the upper and lower end surfaces of the insulating substrate. The bottom of the inductor body after being wrapped with the copper foil extends into the deposition groove, and the inner and outer annular surfaces of the copper foil are both covered with an insulating layer.

[0018] As a preferred solution, a first epoxy resin glue and a second epoxy resin glue are respectively provided on the front end area of ​​the insulating substrate and the rear end area of ​​the insulating substrate, the first epoxy resin glue is used to bond and fix the upper sections of the first pin and the fourth pin to the corresponding first pin through hole and the fourth pin through hole, and the second epoxy resin glue is used to bond and fix the upper sections of the second pin and the third pin to the corresponding second pin through hole and the third pin through hole;

[0019] Furthermore, the first epoxy resin glue and the second epoxy resin glue are respectively located on the front and rear sides of the inductor body, and are correspondingly bonded and fixed to the front and rear sides of the inductor body.

[0020] As a preferred solution, the PFC inductor is mounted on a PCB board, a plurality of conductive holes are provided on the PCB board, the bottom of the insulating substrate is against the top of the PCB board, and the lower sections of the first pin, the second pin, the third pin, and the fourth pin are all extended into the corresponding conductive holes; auxiliary epoxy resin glue is provided on the top of the PCB board corresponding to the front and rear sides of the insulating substrate, and the auxiliary epoxy resin glue is bonded and fixed to the PCB board, the insulating substrate and the corresponding first epoxy resin glue or the second epoxy resin glue.

[0021] Compared with the prior art, the utility model has obvious advantages and beneficial effects. Specifically, it can be seen from the above technical scheme that the main feature is that two windings are integrated and arranged on the same vertical magnetic ring. Compared with two PFC inductors, the overall occupied space is reduced, especially the arrangement of the two windings is ingenious. By reserving a top non-winding area at the top of the vertical magnetic ring, the first winding and the second winding are respectively located on the left and right sides of the top non-winding area. Under the premise of ensuring the outer diameter of the vertical magnetic ring and the area of ​​the winding arrangement region, the product height is further reduced. Moreover, the copper foil is subsequently bonded and fixed to the bottom and top non-winding areas of the inductor body respectively, and the left and right sides of the copper foil are naturally bent to form a gap with the outside of the winding, which is convenient for the heat dissipation of the winding.

[0022] In order to more clearly illustrate the structural features and functions of the present invention, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a front view of a PFC inductor according to the first embodiment of the utility model;

[0024] Figure 2 It is a side view of a PFC inductor according to the first embodiment of the utility model;

[0025] Figure 3 This is a bottom view of a PFC inductor according to the first embodiment of the utility model;

[0026] Figure 4 This is a winding diagram of a PFC inductor according to the first embodiment of the utility model;

[0027] Figure 5 This is an electrical connection diagram of a PFC inductor according to the first embodiment of the utility model;

[0028] Figure 6 This is a front view of a PFC inductor according to the second embodiment of the present utility model;

[0029] Figure 7 is a cross-sectional view of a PFC inductor according to the second embodiment of the present utility model;

[0030] Figure 8 This is a bottom view of a PFC inductor according to the second embodiment of the utility model;

[0031] Fig. 9 This is a winding diagram of a PFC inductor according to the second embodiment of the utility model;

[0032] Fig.10 This is an application diagram of a PFC inductor installed on a PCB board according to the second embodiment of the utility model;

[0033] Fig.11 This is a structural diagram of a PFC inductor in the second embodiment of the present invention, in which the copper foil is surrounded by the outer periphery of the inductor body.

[0034] Description of the symbols in the accompanying drawings: inductor body 10, vertical magnetic ring 11, top non-winding area 111, bottom non-winding area 112, first winding 12, second winding 13, copper foil 20, external lead 21, insulating substrate 30, deposition groove 31, first epoxy resin glue 301, second epoxy resin glue 302, PCB board 40, auxiliary epoxy resin glue 41, first pin through hole 1, second pin through hole 2, third pin through hole 3, fourth pin through hole 4. DETAILED DESCRIPTION

[0035] Please refer to Figures 1 to 11 As shown, it shows the specific structure of various embodiments of the present utility model.

[0036] In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "up", "down", "left", "right", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0037] A PFC inductor comprises an inductor body 10, a copper foil 20 and an insulating substrate 30. The PFC inductor is mounted on a horizontal PCB board 40.

[0038] The inductor body 10 includes a vertical magnetic ring 11, a first winding 12 and a second winding 13. The axial direction of the inner ring hole of the vertical magnetic ring 11 extends in the front-back direction. The first winding 12 is wound upward from the bottom of the vertical magnetic ring 11 to the left to the top of the vertical magnetic ring 11 to form a layer of winding, and then wound downward from the left to the bottom of the vertical magnetic ring 11 to form a second layer of winding. The second winding 13 is wound upward from the bottom of the vertical magnetic ring 11 to the right to the top of the vertical magnetic ring 11 to form a layer of winding, and then wound downward from the right to the bottom of the vertical magnetic ring 11 to form a second layer of winding. In addition, a top non-winding area 111 is reserved at the top of the vertical magnetic ring 11, so that the first winding 12 and the second winding 13 are respectively located on the left and right sides of the top non-winding area 111. The outer circumferential side of the inductor body 10 is covered with insulating tape. The first winding 12 and the second winding 13 are both wound in a repeated overlapping manner, which is conducive to suppressing electromagnetic interference signals. In actual production, the wire diameters of the first winding 12 and the second winding 13 may be different, and the number of turns may also be different. For example, the wire diameter of the first winding 12 is 1.00 to 1.15 mm, and the wire diameter of the second winding 13 is 0.50 to 0.60 mm.

[0039] The copper foil 20 is wrapped around the outer circumference of the inductor body 10, and the copper foil 20 is respectively bonded and fixed to the bottom and top non-winding areas 111 of the inductor body 10, so that the left and right areas of the copper foil 20 and the left and right areas of the inductor body 10 form gaps A respectively. Specifically, the copper foil 20 is formed into an ellipse by band-shaped enclosure and jointing, and the joint of the copper foil 20 is located above the bottom of the vertical magnetic ring 11 and maintains a vertical spacing with the insulating substrate 30. The copper foil 20 is connected with an external lead 21, and the welding point of the external lead and the copper foil 20 is located above the bottom of the vertical magnetic ring 11 and maintains a vertical spacing with the insulating substrate 30. The welding point B between the external lead and the copper foil and the joint C of the copper foil are respectively located on the left and right sides of the inductor body 10. A bottom non-winding area 112 is reserved at the bottom of the vertical magnetic ring 11 , so that the first winding 12 and the second winding 13 are respectively located on the left and right sides of the bottom non-winding area 112 , and the copper foil 20 is bonded and fixed to the bottom non-winding area 112 .

[0040] The insulating substrate 30 is horizontally extended, and is provided with a first pin through hole 1, a second pin through hole 2, a third pin through hole 3 and a fourth pin through hole 4. The first pin through hole and the fourth pin through hole are located on the insulating substrate 30 near the front end area, and the second pin through hole and the third pin through hole are located on the insulating substrate 30 near the rear end area; the first winding 12 has a first pin and a second pin located at the bottom of the vertical magnetic ring 11, and the second winding 13 has a third pin and a fourth pin located at the bottom of the vertical magnetic ring 11; the inductor body 10 wrapped with the copper foil 20 is located on the insulating substrate 30, and the first pin, the second pin, the third pin and the fourth pin pass through the corresponding first pin through hole, the second pin through hole, the third pin through hole and the fourth pin through hole.

[0041] Further, as shown in the second embodiment, the insulating substrate 30 may be provided with a sinking groove 31, the sinking groove 31 passes through the upper and lower end surfaces of the insulating substrate 30, and the bottom of the inductor body 10 after wrapping the copper foil 20 extends into the sinking groove 31, and the inner and outer annular surfaces of the copper foil 20 are covered with an insulating layer, and the insulating layer refers to a tape respectively attached to the inner and outer annular surfaces of the copper foil 20. The bandwidth of the tape usually used is wider than the bandwidth of the copper foil 20, so that the front and rear ends of the tape can be folded back and attached to the opposite side of the copper foil 20, for example, The front and rear ends of the tape attached to the outer ring surface of the copper foil 20 are folded inwards and then attached to the inner ring surface of the copper foil 20. In this way, it is ensured that the tape is firmly attached to the copper foil 20, and the copper foil 20 is bonded and fixed to the bottom non-winding area and the top non-winding area respectively. Glue can be used for bonding and fixing, or a wider tape can be attached to the top and bottom positions of the inner ring surface of the copper foil 20, and then the front and rear ends of the tape that extend beyond the copper foil 20 are folded inwards so that the adhesive surface of the folded tape part faces the magnetic ring to be bonded to the magnetic ring (specifically, the top and bottom positions of the outer ring surface of the magnetic ring).

[0042] A first epoxy resin glue 301 and a second epoxy resin glue 302 are respectively disposed on the front end region and the rear end region of the insulating substrate 30. The first epoxy resin glue 301 adheres and fixes the upper sections of the first pin and the fourth pin to the corresponding first pin through hole and the fourth pin through hole, and the second epoxy resin glue 302 adheres and fixes the upper sections of the second pin and the third pin to the corresponding second pin through hole and the third pin through hole; and the first epoxy resin glue 301 and the second epoxy resin glue 302 are respectively located at the front and rear sides of the inductor body 10, and are correspondingly adhered and fixed to the front and rear sides of the inductor body 10. Usually, a sleeve D is sleeved on the upper part of the first pin, the second pin, the third pin, and the fourth pin. The sleeve D can be fixed on the corresponding pin by heat shrinking to play an insulating protection role. At the same time, the corresponding pin with the sleeve is inserted into the corresponding pin through hole, which has better stability during pre-installation. The lower part of the corresponding pin is used to form an electrical connection with the PCB board 40, which exposes the conductor. The outside of the conductor is tinned to form a cylindrical shape with a slightly larger radius than the original conductor, which is better combined with the corresponding conductive hole of the PCB board 40, and welding at the bottom of the PCB board 40 is simpler and has good welding reliability.

[0043] The PFC inductor is mounted on a PCB board 40 , which is provided with a plurality of conductive holes. The bottom of the insulating substrate 30 is against the top of the PCB board 40 , and the bottom of the inductor body 10 is in contact with the top of the PCB board 40 or maintains a slight gap. The lower sections of the first pin, the second pin, the third pin and the fourth pin are all extended into the corresponding conductive holes; the top of the PCB board 40 is provided with auxiliary epoxy resin glue 41 corresponding to the front and rear sides of the insulating substrate 30, and the auxiliary epoxy resin glue 41 is bonded and fixed to the PCB board 40, the insulating substrate 30 and the corresponding first epoxy resin glue 301 or the second epoxy resin glue 302. In this way, on the one hand, the auxiliary epoxy resin glue 41 is more firmly combined with the corresponding first epoxy resin glue 301 or the second epoxy resin glue 302, which is conducive to the stable connection of multiple components. On the other hand, after being installed on the PCB board 40, the front and rear epoxy resin glue protrusions are retained, and the PCB board 40 is regular and not messy.

[0044] The design focus of the utility model is that it mainly integrates two windings on the same vertical magnetic ring. Compared with two PFC inductors, the overall occupied space is reduced, especially the arrangement of the two windings is ingenious. By reserving a top non-winding area at the top of the vertical magnetic ring, the first winding and the second winding are respectively located on the left and right sides of the top non-winding area. Under the premise of ensuring the outer diameter of the vertical magnetic ring and the area of ​​the winding arrangement region, the product height is further reduced. Moreover, the copper foil is subsequently bonded and fixed to the bottom and top non-winding areas of the inductor body respectively, and the left and right sides of the copper foil are naturally bent to form a gap with the outside of the winding, which is convenient for the heat dissipation of the winding.

[0045] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any slight modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A PFC inductor, characterized in that: Included An inductor body, the inductor body comprising a vertical magnetic ring, a first winding and a second winding, the inner ring hole of the vertical magnetic ring is axially extended in the front-to-back direction; the first winding is wound upward to the left along the bottom of the vertical magnetic ring to the top of the vertical magnetic ring, and then wound downward to the left to the bottom of the vertical magnetic ring; the second winding is wound upward to the right along the bottom of the vertical magnetic ring to the top of the vertical magnetic ring, and then wound downward to the right to the bottom of the vertical magnetic ring; and a top non-winding area is reserved at the top of the vertical magnetic ring, so that the first winding and the second winding are respectively located on the left and right sides of the top non-winding area; the outer ring circumference of the inductor body is covered with insulating tape; The copper foil is wrapped around the outer circumference of the inductor body, and the copper foil is bonded and fixed to the bottom and top non-winding areas of the inductor body respectively, so that the left and right areas of the copper foil and the left and right areas of the inductor body form gaps respectively.

2. The PFC inductor according to claim 1, characterized in that: Also included is an insulating substrate; The insulating substrate is horizontally extended, and a first pin through hole, a second pin through hole, a third pin through hole and a fourth pin through hole are provided on the insulating substrate, the first pin through hole and the fourth pin through hole are located in the front end area of ​​the insulating substrate, and the second pin through hole and the third pin through hole are located in the rear end area of ​​the insulating substrate; The first winding has a first pin and a second pin located at the bottom of the vertical magnetic ring, and the second winding has a third pin and a fourth pin located at the bottom of the vertical magnetic ring; the inductor body wrapped with the copper foil is located on the insulating substrate, and the first pin, the second pin, the third pin, and the fourth pin pass through the corresponding first pin through hole, the second pin through hole, the third pin through hole, and the fourth pin through hole.

3. The PFC inductor according to claim 2, characterized in that: The copper foil is formed into an elliptical shape by band-shaped enclosure and bonding. The bonding part of the copper foil is located above the bottom of the vertical magnetic ring and maintains a vertical spacing with the insulating substrate.

4. The PFC inductor according to claim 3, characterized in that: The copper foil is connected with an external lead wire, and the welding point between the external lead wire and the copper foil is located above the bottom of the vertical magnetic ring and maintains a vertical spacing with the insulating substrate.

5. The PFC inductor according to claim 4, characterized in that: The welding point between the external lead and the copper foil and the joining point of the copper foil are respectively located on the left and right sides of the inductor body.

6. The PFC inductor according to claim 2, characterized in that: A bottom non-winding area is reserved at the bottom of the vertical magnetic ring, so that the first winding and the second winding are respectively located on the left and right sides of the bottom non-winding area, and the copper foil is bonded and fixed to the bottom non-winding area.

7. A PFC inductor according to claim 2 or 6, characterized in that: The insulating substrate is provided with a sinking groove which passes through the upper and lower end surfaces of the insulating substrate. The bottom of the inductor body wrapped with the copper foil extends into the sinking groove, and the inner and outer annular surfaces of the copper foil are both covered with an insulating layer.

8. The PFC inductor according to claim 7, characterized in that: A first epoxy resin glue and a second epoxy resin glue are respectively disposed on the front end area of ​​the insulating substrate and the rear end area of ​​the insulating substrate, wherein the first epoxy resin glue is used to bond and fix the upper sections of the first pin and the fourth pin to the corresponding first pin through hole and the fourth pin through hole, and the second epoxy resin glue is used to bond and fix the upper sections of the second pin and the third pin to the corresponding second pin through hole and the third pin through hole; Furthermore, the first epoxy resin glue and the second epoxy resin glue are respectively located on the front and rear sides of the inductor body, and are correspondingly bonded and fixed to the front and rear sides of the inductor body.

9. The PFC inductor according to claim 8, characterized in that: The PFC inductor is mounted on a PCB board, and a plurality of conductive holes are provided on the PCB board. The bottom of the insulating substrate is against the top of the PCB board, and the lower sections of the first pin, the second pin, the third pin, and the fourth pin are all extended into the corresponding conductive holes; auxiliary epoxy resin glue is provided on the top of the PCB board corresponding to the front and rear sides of the insulating substrate, and the auxiliary epoxy resin glue is bonded and fixed to the PCB board, the insulating substrate, and the corresponding first epoxy resin glue or the second epoxy resin glue.

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