Novel resonant inductor with segmented air gaps
By designing segmented air gaps and interlaced and bonded core columns in the resonant inductor, the problems of poor eddy current loss and heat dissipation of existing resonant inductors are solved, and more efficient inductance performance and lower power loss are achieved.
Patent Information
- Application Number
- CN202420429330.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-03-06
- Publication Date
- 2025-02-18
- Estimated Expiration
- 2034-03-06
AI Technical Summary
The existing resonant inductor has a large air gap, resulting in poor eddy current loss and heat dissipation effect, which may cause wire insulation failure and ultimately product failure.
A new type of resonant inductor of segmented air gap was designed. By setting two integrated series resonant inductors, the number of air gaps and the distance between the column ring air gaps is controlled, and the core columns are staggeredly bonded with ceramic sheets and magnetic chips. Improve thermal conductivity.
It effectively reduces eddy current loss, improves heat dissipation effect, improves the efficiency of the resonant inductor by more than 15%, and effectively reduces power loss.
Smart Images
Figure CN222507324U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of inductor equipment, in particular to a novel segmented air-gap resonant inductor. Background Art
[0002] Magnetic components commonly used in power electronic products, such as transformers and inductors, usually need to form an air gap on the magnetic core to adjust the inductance of the product, and the leakage of magnetic lines near the air gap will form eddy currents, which will in turn cause loss and heat. The air gap of the resonant inductor is large, while the space in the middle column is usually small. The conventional segmented air gap is large, and the actual effect of reducing eddy current loss is not ideal, and the heat dissipation effect is poor. When the loss and heat are serious, it may cause the wire insulation failure, and ultimately lead to product failure.
[0003] To achieve the above objectives, the utility model provides a novel segmented air-gap resonant inductor, which can solve the problems raised in the above background technology. Utility Model Content
[0004] The utility model adopts the following technical solutions to achieve:
[0005] A novel resonant inductor with segmented air gap comprises an integrated inductor box and a bearing base. Two inductor mounting seats are arranged inside the integrated inductor box. Integrated inductor coils are respectively connected inside the two inductor mounting seats. The two inductor mounting seats are separated from each other. A magnetic core center column is arranged between the two inductor mounting seats. The magnetic core center column comprises a ceramic sheet, a magnetic core sheet, and a magnetic column sheet. An inductor air gap is provided between the ceramic sheet, the magnetic core sheet, and the magnetic column sheet.
[0006] Preferably, the two integrated inductor coils are connected in series, and the integrated inductor coils are resonant inductors.
[0007] Preferably, the central column of the magnetic core is formed by staggered bonding, and its two ends are magnetic column sheets, and a ceramic sheet-magnetic core sheet-ceramic sheet which are staggeredly bonded in sequence are connected between the two magnetic column sheets.
[0008] Preferably, the ceramic sheet is a perforated ceramic sheet, and the thermal conductivity of the ceramic sheet is 10 W / mK.
[0009] Preferably, six inductor air gaps are arranged inside the middle column of the magnetic core by means of a staggered bonding method, and an air gap is provided between the magnetic column sheet and the ceramic sheet.
[0010] Preferably, the integrated inductor coil is located on the peripheral side of the core center column, and a column ring air gap is provided between the integrated inductor box and the core center column, and the distance of the column ring air gap is greater than 4 times the distance of the inductor air gap.
[0011] Preferably, the integrated inductor coil is a film-wrapped square coil, the cross-section of which is elliptical on both sides, and an adaption groove is provided inside the inductor mounting seat for shaping the integrated inductor coil.
[0012] Compared with the prior art, the beneficial effects of the utility model are:
[0013] The utility model reduces the inductance of a single winding and eddy current loss by setting two integrated series resonant inductors, and reduces eddy current loss by controlling the number of air gaps and the distance between the column ring air gaps; in addition, segmented gaps are used to process the core column, and the heat conduction effect is improved by staggered bonding of magnetic core pieces and ceramic pieces, so that the efficiency of the resonant inductor of the utility model is increased by more than 15% and the power loss can be effectively reduced. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 It is a schematic diagram of the structure of the utility model;
[0015] Figure 2 This is a schematic diagram of the bottom of the load-bearing base structure of the utility model;
[0016] Figure 3 It is a structural schematic diagram of the magnetic core center column of the utility model;
[0017] Figure 4 It is a side view and a partial cross-sectional schematic diagram of the utility model;
[0018] Figure 5 It is a front view and a partial cross-sectional schematic diagram of the utility model.
[0019] In the figure: 1. integrated inductor box; 2. supporting base; 3. magnetic core center column; 4. ceramic sheet; 5. integrated inductor coil; 6. inductor air gap; 7. column ring air gap; 8. magnetic chip; 9. magnetic column sheet; 10. inductor mounting seat; 11. adaptation slot; 12. air gap. DETAILED DESCRIPTION
[0020] In order to facilitate the understanding of the present invention, the present invention will be described in more detail below with reference to the relevant drawings. Several embodiments of the present invention are given in the drawings, but the present invention can be implemented in different forms and is not limited to the embodiments described in the text. On the contrary, these embodiments are provided to make the content disclosed in the present invention more thorough and comprehensive.
[0021] It should be noted that when an element is referred to as being "fixed on" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this article are for illustrative purposes only.
[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly connected by technicians in the technical field of the present invention. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used in this article includes any and all combinations of one or more related listed items.
[0023] The utility model is further described in detail below in conjunction with the accompanying drawings.
[0024] Please refer to the attached Figure 1-3 , including an integrated inductor box 1 and a bearing base 2, wherein two inductor mounting seats 10 are arranged inside the integrated inductor box 1, and the two inductor mounting seats 10 are respectively connected with integrated inductor coils 5, and the two inductor mounting seats 10 are separated from each other, and a magnetic core column 3 is arranged between the two inductor mounting seats 10, and the magnetic core column includes a ceramic sheet 4, a magnetic core sheet 8, and a magnetic column sheet 9, and an inductor air gap 6 is arranged between the ceramic sheet 4, the magnetic core sheet 8, and the magnetic column sheet 9, and a plurality of interfaces are arranged at the bottom of the bearing base 2, and the upper part of the bearing base 2 is in contact with the bottom of the integrated inductor coil 5. The ceramic sheet 4 is an open-hole ceramic sheet 4, and the thermal conductivity of the ceramic sheet 4 is 10W / mK.
[0025] Core saturation is equivalent to an air-core coil on the primary side of the transformer (equivalent to a short circuit). The current will be very large and will continue to rise until the transformer or fuse is burned out.
[0026] The core air gap is the air gap of the core. Generally, the cores of ferrite and silicon steel are not a whole closed body. The gap left intentionally or unintentionally at the E-shaped docking interface is the core air gap. Therefore, when people do not need a core air gap, they can use a toroidal transformer. When a core air gap is used, the docking gap is deliberately enlarged, or non-magnetic conductive materials such as high-temperature paper are placed in the gap. High-frequency transformers need to have an air gap to prevent core magnetic saturation. There are high-order harmonics in UPS, so an air gap is required. The larger the air gap, the greater the magnetic resistance. The purpose of leaving an air gap in the transformer is to prevent magnetic saturation during operation. The air gap is the gap left at the intersection of the iron core. Its function is to reduce the magnetic permeability, so that the coil characteristics are less dependent on the initial magnetic permeability of the core material; the air gap can avoid magnetic saturation under large AC signals or DC bias, and better control the inductance; when the air gap reduces the magnetic permeability, the number of coil turns is required to be larger, and the related copper loss is also increased, so an appropriate compromise is needed. The utility model provides a ceramic material with a thermal conductivity similar to that of the magnetic core to replace the conventional epoxy The ceramic material is an open-pored ceramic sheet 4, the thermal conductivity of the ceramic sheet 4 is 10W / mK, and the lamination method plays the role of air gap segmentation. At the same time, its specific good thermal conductivity can improve the thermal conductivity effect. The two ends of the two sections of the core column 3 are fixed inside the integrated inductor box 1, and the axis lines of the two core columns 3 are parallel to the side and bottom of the box body. The skewness is checked, and the inductor coil is filled, and the distance between the core column 3 and the inductor coil is controlled to be more than 4 times greater than the inductor air gap 6.
[0027] Please refer to Figure 1 The two integrated inductor coils 5 are connected in series with each other, and the integrated inductor coils 5 are resonant inductors.
[0028] Please pay attention to Figure 5 The magnetic core middle column 3 is formed by staggered bonding, and its two ends are magnetic column sheets 9. The two magnetic column sheets 9 are connected with a ceramic sheet 4-magnetic core sheet 8-ceramic sheet 4 which are staggered and bonded in sequence.
[0029] Please pay attention to Figure 5 Six inductor air gaps 6 are arranged inside the magnetic core middle column 3 by a staggered bonding method, and an air gap 12 is arranged between the magnetic column sheet 9 and the ceramic sheet 4 .
[0030] Please pay attention to Figure 1-3 The integrated inductor coil 5 is located on the peripheral side of the magnetic core center column 3 , and there is a column ring air gap 7 between the integrated inductor box 1 and the magnetic core center column 3 , and the distance of the column ring air gap 7 is greater than 4 times the distance of the inductor air gap 6 .
[0031] Please pay attention to Figure 2 , Figure 3The integrated inductor coil 5 is a membrane-wrapped square coil, and its cross-section is elliptical on both sides. An adaption groove 11 is provided inside the inductor mounting seat 10 for shaping the integrated inductor coil 5.
[0032] The above description of the utility model in combination with the accompanying drawings is an exemplary description. Obviously, the specific implementation of the utility model is not limited to the above-mentioned method. As long as the non-substantial improvements are made by adopting the method concept and technical solution of the utility model, or the concept and technical solution of the utility model are directly applied to other occasions without improvement, they are all within the protection scope of the utility model.
Claims
1. A novel segmented air-gap resonant inductor, characterized in that: The invention comprises an integrated inductor box (1) and a bearing base (2); two inductor mounting seats (10) are arranged inside the integrated inductor box (1); integrated inductor coils (5) are connected to the inside of the two inductor mounting seats (10) respectively; the two inductor mounting seats (10) are spaced apart from each other; a magnetic core center column (3) is arranged between the two inductor mounting seats (10); the magnetic core center column comprises a ceramic sheet (4), a magnetic core sheet (8), and a magnetic column sheet (9); and an inductor air gap (6) is provided between the ceramic sheet (4), the magnetic core sheet (8), and the magnetic column sheet (9).
2. The novel segmented air-gap resonant inductor according to claim 1, characterized in that: The two integrated inductor coils (5) are connected in series with each other, and the integrated inductor coils (5) are resonant inductors.
3. The novel segmented air-gap resonant inductor according to claim 1, characterized in that: The magnetic core middle column (3) is formed by staggered bonding, and its two ends are magnetic column sheets (9). A ceramic sheet (4)-magnetic core sheet (8)-ceramic sheet (4) is connected between the two magnetic column sheets (9) in sequence of staggered bonding.
4. The novel segmented air-gap resonant inductor according to claim 3 is characterized in that: The ceramic sheet (4) is a perforated ceramic sheet (4), and the thermal conductivity of the ceramic sheet (4) is 10 W / mK.
5. The novel segmented air-gap resonant inductor according to claim 3 is characterized in that: Six inductive air gaps (6) are arranged inside the magnetic core middle column (3) by means of a single staggered bonding method, and an air gap (12) is provided between the magnetic column sheet (9) and the ceramic sheet (4).
6. The novel segmented air-gap resonant inductor according to claim 1, characterized in that: The integrated inductor coil (5) is located on the peripheral side of the magnetic core center column (3), and a column ring air gap (7) is provided between the integrated inductor box (1) and the magnetic core center column (3), wherein the distance of the column ring air gap (7) is greater than 4 times the distance of the inductor air gap (6).
7. The novel segmented air-gap resonant inductor according to claim 6 is characterized in that: The integrated inductor coil (5) is a film-wrapped square coil, the cross-section of which is elliptical on both sides, and an adaption groove (11) is provided inside the inductor mounting seat (10) for shaping the integrated inductor coil (5).