Inductor

Abstract

The utility model provides an inductor which comprises an inductor magnetic core and an electrode wire, and the inductor magnetic core is provided with a through hole. The electrode wire comprises a base part and two electrode parts, a heat dissipation hole is defined by the base part, the base part is sleeved with the through hole, the extension direction of the base part is the same as that of the through hole, and the two electrode parts are connected to the two extension ends of the base part respectively and protrude out of the through hole; and each electrode part avoids at least part of hole openings of the heat dissipation holes. The heat generated by the base part in the inductor can be taken away by the airflow passing through the heat dissipation holes, so that the cooling of the base part is realized, and the temperature rise characteristic of the inductor is improved.

Description

Technical Field

[0001] The utility model belongs to the technical field of inductance, and in particular relates to an inductor. Background Art

[0002] In order to meet the high-power characteristics of a graphics processing unit (GPU), higher operating temperature and larger operating current requirements are put forward for the one-piece inductor used for rectification in the power module.

[0003] The current mainstream inductor is made by mixing soft magnetic metal powder with resin, pressing it together with the electrode coil, and then baking it to cure. If it is operated at a high temperature of more than 150°C for a long time, the resin that acts as a bond will age, and the inductance strength of the inductor will deteriorate and fail.

[0004] In order to increase the working temperature of the inductor, a copper-iron co-fired inductor can be used. The preparation process of the inductor is to first press the flat copper wire and the soft magnetic metal powder into an integral shape, and then sinter and solidify in a nitrogen atmosphere. In order to increase the working current, the electrode of the inductor uses a flat copper wire to increase the ability of the electrode to withstand current. Through the above sintering process, the organic matter that plays a bonding role in the solidification and molding has been decomposed and discharged in the early stage of the sintering process, and the soft magnetic metal powders are bonded together by inorganic matter at the grain boundary. After solidification, the lead-out terminal is processed. The high temperature resistance of the inductor made in this way can exceed 150°C.

[0005] The above-mentioned inductor usually uses a flat copper wire placed in the middle of a large and thin magnetic core made of soft magnetic metal powder. The magnetic core is then molded together with the flat copper wire in the middle. The molded inductor is sintered at high temperature under the protection of a reducing atmosphere, and then the lead-out terminals are tinned to become a finished product.

[0006] However, the inductor has poor heat dissipation capacity and cannot continuously dissipate heat. The electrodes made of flat copper wire will gradually oxidize, causing product failure. In addition, the RDC of the inductor has limited room for reduction. The electrodes made of flat copper wire are wide and thick. At this width, the inductance will decrease. The thickness will also reduce the utilization rate of copper. Moreover, it is not easy to bend the lead-out terminals during processing. If the bending force on the terminals is increased, the product may be fractured due to stress. Utility Model Content

[0007] The utility model aims to provide an inductor, aiming to solve the technical problems in the prior art that the flat copper wire has low inductance and is difficult to bend at the end.

[0008] In order to achieve the above purpose, the technical solution adopted by the utility model is as follows:

[0009] An inductor is provided, comprising:

[0010] The inductor core is provided with a through hole;

[0011] The electrode wire includes a base and two electrode parts. The base is arranged to form a heat dissipation hole and is sleeved in the through hole. The extension direction of the base is the same as the extension direction of the through hole. The two electrode parts are respectively connected to the two extension ends of the base and protrude out of the through hole, wherein each of the electrode parts avoids at least part of the opening of the heat dissipation hole.

[0012] As one of the embodiments, the extension length of the base is equal to the extension length of the through hole, and the two extension ends of the base are flush with the two openings of the through hole.

[0013] As one of the implementation modes, the base and the two electrode parts are integrally formed.

[0014] As one of the implementation modes, the electrode portion is in sheet shape and is bent along the circumference of the inductor core, and both of the electrode portions are attached to the outer surface of the inductor core.

[0015] As one of the embodiments, the base includes a first substrate, a second substrate, a third substrate and a fourth substrate connected end to end in sequence, the first substrate, the second substrate, the third substrate and the fourth substrate are jointly arranged to form the heat dissipation hole, the first substrate is parallel to the third substrate, and the second substrate is parallel to the fourth substrate.

[0016] As one of the implementation modes, the two electrode portions are respectively connected to the two extending ends of the first substrate.

[0017] As one of the embodiments, the electrode portion includes a first electrode sheet and a second electrode sheet that are connected and extend in the same direction, the first electrode sheet is connected to the first substrate and is arranged at an angle to the first substrate, the second electrode sheet is arranged at an angle to the first electrode sheet, and the first electrode sheet and the second electrode sheet are both attached to the outer surface of the inductor core.

[0018] As one of the embodiments, the inductor core has a first end face, a second end face, a first outer surface, a second outer surface, a third outer surface and a fourth outer surface, the first outer surface, the second outer surface, the third outer surface and the fourth outer surface are connected end to end in sequence, the first end face and the second end face are opposite to each other, and both are connected to the first outer surface, the second outer surface, the third outer surface and the fourth outer surface, the through hole passes through the first end face and the second end face, the first electrode sheets of the two electrode parts are respectively attached to the first end face and the second end face, and the second electrode sheets of the two electrode parts are both attached to the first outer surface and are spaced apart.

[0019] As one of the implementation modes, the first electrode sheet is perpendicular to the first substrate, and the second electrode sheet is perpendicular to the first electrode sheet.

[0020] As one of the embodiments, a groove is formed on the first outer surface, and the second electrode sheet is at least partially received in the groove and adheres to the bottom surface of the groove.

[0021] The technical effect of the utility model relative to the prior art is as follows: the inductor replaces the base of the current solid electrode wire with a tubular base, and the base is connected to the outside through a heat dissipation hole. The heat generated by the base can be dissipated into the air of the heat dissipation hole, and the hot air in the heat dissipation hole can be taken away by the airflow passing through the heat dissipation hole, thereby achieving cooling of the base and improving the temperature rise characteristics of the inductor. The two electrode parts avoid the openings of the heat dissipation holes to avoid blocking the discharge of hot air in the heat dissipation holes. In addition, the width of the tubular base is the circumference of the base, which doubles the width compared to the base of the current solid electrode wire. In this way, the RDC of the inductor can be reduced without changing the external dimensions of the entire inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the utility model, the drawings required for use in the embodiments of the utility model or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0023] Figure 1 is a three-dimensional structural diagram of an inductor provided in an embodiment of the utility model;

[0024] Figure 2 for Figure 1 A three-dimensional structural diagram of the electrode wire of the inductor;

[0025] Figure 3is a three-dimensional structural diagram of the electrode wire of the inductor in some embodiments of the utility model;

[0026] Figure 4 It is a schematic diagram of the structure of two magnetic core parts clamping the base;

[0027] Figure 5 It is a schematic diagram of the structure after the inductor core and the electrode wire are combined.

[0028] Description of reference numerals:

[0029] 10. Inductor core; 101. Through hole; 11. Magnetic core portion; 1011. First outer surface; 1012. Second outer surface; 1013. Third outer surface; 1014. Fourth outer surface; 1015. First end surface; 1016. Second end surface; 20. Electrode line; 21. Base portion; 211. First substrate; 212. Second substrate; 213. Third substrate; 214. Fourth substrate; 22. Electrode portion; 221. First electrode sheet; 222. Second electrode sheet; 201. Heat dissipation hole. DETAILED DESCRIPTION

[0030] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0031] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0032] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present utility model, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0033] In the present invention, unless otherwise clearly specified and limited, the terms "install", "connect", "connect", "fix" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0034] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0035] For ease of understanding, the English abbreviations appearing in the text are explained below:

[0036] RDC: refers to the resistance value of the inductor under direct current. The full name is Remote Differential Compression.

[0037] See also Figure 1 The utility model provides an inductor, including an inductor core 10 and an electrode wire 20.

[0038] The inductor core 10 is provided with a through hole 101 . The through hole 101 can extend along a straight line and penetrate the inductor core 10 .

[0039] The electrode line 20 includes a base 21 and two electrode parts 22. The base 21 is in a straight tube shape and is surrounded by a heat dissipation hole 201. The heat dissipation hole 201 passes through the base 21 along the extension direction of the base 21. The base 21 is sleeved in the through hole 101 and is adapted to the through hole 101. The extension direction of the base 21 is the same as the extension direction of the through hole 101. The two electrode parts 22 are respectively connected to the two extension ends of the base 21 and protrude outside the through hole 101, wherein the two electrode parts 22 avoid the two openings of the heat dissipation hole 201. The base 21 is used to store magnetic energy and provide inductance, and the two electrode parts 22 are used to connect the inductor to the circuit.

[0040] The inductor replaces the base 21 of the current solid electrode wire 20 with a tubular base 21. The base 21 is connected to the outside through a heat dissipation hole 201. The heat generated by the base 21 can be dissipated into the air of the heat dissipation hole 201. The hot air in the heat dissipation hole 201 can be taken away by the airflow passing through the heat dissipation hole 201, thereby achieving cooling of the base 21 and improving the temperature rise characteristics of the inductor. The two electrode parts 22 avoid the opening of the heat dissipation hole 201 to avoid blocking the discharge of the hot air in the heat dissipation hole 201. In addition, the width of the tubular base 21 is the circumference of the base 21. Compared with the base 21 of the current solid electrode wire 20, the width is doubled. In this way, the RDC of the inductor can be reduced without changing the external dimensions of the entire inductor.

[0041] Among them, the through hole 101 on the inductor core 10 can be formed by docking two magnetic cores to facilitate clamping the electrode wire 20, thereby realizing the connection between the inductor core 10 and the electrode wire 20. The through hole 101 can also be opened in the middle position of a magnetic core. In this case, the electrode wire 20 can be inserted into the through hole 101 to realize the connection with the inductor core 10.

[0042] In some embodiments, see Figure 1 The extension length of the base 21 is equal to the extension length of the through hole 101, and the two extension ends of the base 21 are flush with the two openings of the through hole 101. In this way, the base 21 is completely received in the through hole 101, and the surface area of ​​the base 21 is maximized to reduce the RDC of the inductor.

[0043] In some embodiments, the base 21 and the electrode 22 can be made of copper to ensure high conductivity and thermal stability. For ease of processing, the base 21 and the two electrode 22 are integrally formed. Figure 1 The electrode part 22 can be connected to the opening edge of the heat dissipation hole 201 of the base 21. In this way, during processing, the electrode wire 20 can be processed through the copper tube.

[0044] In some embodiments, see Figure 2 The base 21 includes a first substrate 211, a second substrate 212, a third substrate 213 and a fourth substrate 214 which are connected end to end in sequence. The first substrate 211, the second substrate 212, the third substrate 213 and the fourth substrate 214 are arranged together to form a heat dissipation hole 201. The first substrate 211 is parallel to the third substrate 213, and the second substrate 212 is parallel to the fourth substrate 214. At this time, the cross section of the base 21 is a square, which not only realizes the thinning of the base 21, but also facilitates assembly with the inductor core 10.

[0045] Optional, see Figure 2The electrode portion 22 is in sheet shape and is bent along the circumference of the inductor core 10. Both electrode portions 22 are attached to the outer surface of the inductor core 10. In this way, the space occupied by the inductor can be reduced. At the same time, the two electrode portions 22 can be bent and buckled on the inductor core 10, thereby improving the overall structural stability of the inductor.

[0046] There are many ways to form the electrode portion 22, for example Figure 3 , the copper tube is divided into two ends and a base 21 located between the two ends, a portion of the copper tube at the end is removed radially, and the remaining sheet-like portion is the electrode portion 22, and the base 21 is still tubular. The electrode portion 22 formed in this way is easy to bend after cutting, and damage due to excessive thickness during the bending process can be avoided. It is also possible to cut off a portion between the end and the base 21, and then flatten the end to form a sheet-like electrode portion 22, which is not limited here.

[0047] Of course, the electrode portion 22 may also be tubular, which is not limited here, as long as it avoids at least part of the opening of the heat dissipation hole 201 .

[0048] Optional, see Figure 2 The two electrode portions 22 are respectively connected to the two extending ends of the first substrate 211. In this way, the two electrode portions 22 can be bent in the same direction so that the two electrodes of the inductor connected to the circuit are located on the same side, which facilitates the electrical connection between the inductor and the circuit.

[0049] For further information, see Figure 1 and Figure 2 The electrode portion 22 includes a first electrode sheet 221 and a second electrode sheet 222 that are connected and extend in the same direction. The first electrode sheet 221 is connected to the first substrate 211 and is arranged at an angle with the first substrate 211. The second electrode sheet 222 is arranged at an angle with the first electrode sheet 221. The first electrode sheet 221 and the second electrode sheet 222 are both attached to the outer surface of the inductor core 10. It can be understood that the bending angle between the first electrode sheet 221 and the second electrode sheet 222 is adapted to the angle at the corner of the inductor core 10, so that the first electrode sheet 221 and the second electrode sheet 222 can be attached to the outer surface of the inductor core 10. At the same time, the second electrode sheets 222 of the two electrode portions 22 are bent toward each other and can be close to each other for easy access to the circuit.

[0050] Specifically, see Figure 1 and Figure 2The inductor core 10 may be hexahedral, and the inductor core 10 has a first end face 1015, a second end face 1016, a first outer surface 1011, a second outer surface 1012, a third outer surface 1013, and a fourth outer surface 1014. The first outer surface 1011, the second outer surface 1012, the third outer surface 1013, and the fourth outer surface 1014 are connected end to end in sequence and are jointly arranged to form a heat dissipation hole 201. The first end face 1015 and the second end face 1016 are connected to each other end to end. 016 are opposite to each other and are connected to the first outer surface 1011, the second outer surface 1012, the third outer surface 1013 and the fourth outer surface 1014. The through hole 101 passes through the first end surface 1015 and the second end surface 1016. The first electrode sheets 221 of the two electrode parts 22 are respectively attached to the first end surface 1015 and the second end surface 1016. The second electrode sheets 222 of the two electrode parts 22 are both attached to the first outer surface 1011 and are spaced apart to avoid short circuit. In this way, the second electrode sheets 222 of the two electrode parts 22 can be located on the same surface of the inductor magnetic core 10.

[0051] Optional, see Figure 1 and Figure 2 , the inductor core 10 is in a tetrahedral shape for easy processing. Among them, the first outer surface 1011 is parallel to the third outer surface 1013, the second outer surface 1012 is parallel to the fourth outer surface 1014, the first outer surface 1011 is perpendicular to the second outer surface 1012 and parallel to each other, the first end surface 1015 is parallel to the second end surface 1016, and both are perpendicular to the first outer surface 1011. At this time, the first electrode sheet 221 is perpendicular to the first substrate 211, and the first electrode sheet 221 is perpendicular to the second electrode sheet 222 to adapt to the shape of the inductor core 10. In practical applications, the shape of the inductor core 10 can be set as needed, and there is no limitation here.

[0052] In order to protect the second electrode sheet 222, a groove can be formed on the first outer surface 1011, and the second electrode sheet 222 is at least partially contained in the groove and fits the groove bottom surface of the groove. It can be understood that the groove bottom surface of the groove is a part of the second outer surface 1012. There are two grooves formed on the first outer surface 1011, the two grooves are spaced apart, and respectively penetrate to the first end face 1015 and the second end face 1016, the first electrode sheet 221 extends from the orifice of the through hole 101 to the notch of the groove, and the second electrode sheet 222 extends in the groove along the extension direction of the groove, the second electrode sheet 222 can be adapted to the groove, and the groove can limit the electrode part 22 to improve the structural stability of the electrode part 22. In the actual processing process, the second electrode sheet 222 can be embedded in the inductor core 10 by squeezing the second electrode sheet 222, thereby forming two grooves on the inductor core 10. Alternatively, two grooves can be first opened on the inductor core 10, and then the second electrode sheet 222 can be bent into the grooves during the bending process of the electrode portion 22. There is no limitation here.

[0053] In some embodiments, the method for preparing the inductor core 10 includes the following steps:

[0054] S1, subjecting carbonyl iron powder, amorphous iron powder, and atomized alloy powder to surface SiO2 or ceramic insulation coating treatment, and then mixing one or more of the treated carbonyl iron powder, amorphous iron powder, and atomized alloy powder with anhydrous ethanol or acetone or other solvents for 30-40 minutes to form a powder-solvent mixed slurry, wherein the mass percentage of the anhydrous ethanol or acetone or other solvents is 10-15wt%;

[0055] S2, mixing 3-5wt% of the thermosetting epoxy resin with an equal mass of anhydrous ethanol or acetone or other solvents and stirring for 10-20 minutes to make the thermosetting epoxy resin form a solution state;

[0056] S3, pouring the thermosetting epoxy resin solution in step S2 into the powder solvent mixed slurry in step S1 to form loose moist soil particles, and then kneading them in a kneader for 40-60 minutes until the loose moist soil particles are no longer attached to the kneader blades;

[0057] S4, pour the loose moist soil particles into a reciprocating granulator, and pass through a 50-80 mesh sieve for granulation;

[0058] S5. Bake the prepared pellets at 50° C. for 60-90 minutes until they are dry, forming an inductor core 10 for use.

[0059] In some embodiments, a method for assembling an inductor includes the following steps:

[0060] P1. Cut off a section of cylindrical thin copper tube, cut off a part of each end radially, and leave a sheet of copper. The uncut part in the middle forms the base 21 of the electrode line 20, and the remaining sheet of copper at the two ends forms the electrode part 22 of the electrode line 20. Figure 3 ;

[0061] P2, flatten the base 21 and keep a certain gap, the gap forms the heat dissipation hole 201 of the base 21, and at the same time, pre-press the granules prepared in step S4 of the above-mentioned inductor core 10 preparation method into two flat core parts 11 under a low pressure of 5-10MPa and without heating, as shown in FIG. Figure 4 ;

[0062] P3, clamp the two magnetic core parts 11 up and down around the base 21 processed in step P2, as shown in FIG. Figure 4 , preheat at 100-120°C for 60-100 seconds in the mold cavity, and then maintain the pressure at 130-150°C for 60-80 seconds at a pressure of 600-900 MPa to completely bond and solidify the inductor core 10 and the base 21 together, such as Figure 5 ;

[0063] P4, bend the two electrode parts 22 in a direction away from the opening of the heat dissipation hole 201 until the first electrode sheet 221 of the electrode part 22 is attached to the first end surface 1015 of the inductor core 10, and the second electrode sheet 222 of the electrode part 22 is attached to the second end surface 1016 of the inductor core 10, and the second electrode sheets 222 of the two electrode parts 22 protruding from the inductor core 10 are bent toward each other again until the two second electrode sheets 222 are also attached to the inductor core 10, and the two second electrode sheets 222 are pressed toward the inductor core 10 until the two second electrode sheets 222 are embedded in the inductor core 10, to obtain an initial product, such as Figure 1 ;

[0064] P5. Place the initial product in an atmosphere furnace, raise the temperature from room temperature to 750-900°C within 6 hours under nitrogen flow, and then keep it warm for 2 hours to obtain a finished inductor.

[0065] The above description is only a preferred embodiment of the utility model, and only specifically describes the technical principle of the utility model. These descriptions are only for explaining the principle of the utility model and cannot be interpreted as limiting the protection scope of the utility model in any way. Based on the explanation here, any modification, equivalent replacement and improvement made within the spirit and principle of the utility model, and other specific implementation methods of the utility model that can be associated with the technicians in this field without creative labor, should be included in the protection scope of the utility model.

Claims

1. An inductor, characterized in that: include: The inductor core is provided with a through hole; The electrode wire includes a base and two electrode parts. The base is arranged to form a heat dissipation hole and is sleeved in the through hole. The extension direction of the base is the same as the extension direction of the through hole. The two electrode parts are respectively connected to the two extension ends of the base and protrude out of the through hole, wherein each of the electrode parts avoids at least part of the opening of the heat dissipation hole.

2. The inductor according to claim 1, wherein: The extension length of the base is equal to the extension length of the through hole, and the two extension ends of the base are flush with the two openings of the through hole.

3. The inductor according to claim 1, wherein: The base and the two electrode parts are integrally formed.

4. The inductor according to claim 1, wherein: The electrode part is in sheet shape and is bent along the circumferential direction of the inductor core. Both electrode parts are attached to the outer surface of the inductor core.

5. The inductor according to claim 4, wherein: The base includes a first substrate, a second substrate, a third substrate and a fourth substrate connected end to end in sequence, the first substrate, the second substrate, the third substrate and the fourth substrate are jointly arranged to form the heat dissipation hole, the first substrate is parallel to the third substrate, and the second substrate is parallel to the fourth substrate.

6. The inductor according to claim 5, wherein: The two electrode portions are respectively connected to the two extending ends of the first substrate.

7. The inductor according to claim 6, wherein: The electrode portion includes a first electrode sheet and a second electrode sheet which are connected and extend in the same direction. The first electrode sheet is connected to the first substrate and is arranged at an angle with the first substrate. The second electrode sheet is arranged at an angle with the first electrode sheet. The first electrode sheet and the second electrode sheet are both attached to the outer surface of the inductor core.

8. The inductor according to claim 7, wherein: The inductor core has a first end face, a second end face, a first outer surface, a second outer surface, a third outer surface and a fourth outer surface. The first outer surface, the second outer surface, the third outer surface and the fourth outer surface are connected end to end in sequence. The first end face and the second end face are opposite to each other and are both connected to the first outer surface, the second outer surface, the third outer surface and the fourth outer surface. The through hole passes through the first end face and the second end face. The first electrode sheets of the two electrode parts are respectively attached to the first end face and the second end face. The second electrode sheets of the two electrode parts are both attached to the first outer surface and are spaced apart.

9. The inductor according to claim 8, wherein: The first electrode sheet is perpendicular to the first substrate, and the second electrode sheet is perpendicular to the first electrode sheet.

10. The inductor according to claim 8, wherein A groove is formed on the first outer surface, and the second electrode sheet is at least partially received in the groove and adheres to the bottom surface of the groove.

Images