Inductor
Through the combined design of laminate winding loop, the high loss and interlayer peeling problems caused by air gap opening in high-power inductors are solved, and a low loss, low cost and high filling rate inductor design is achieved.
Patent Information
- Application Number
- CN202421001345.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-10
- Publication Date
- 2025-02-25
- Estimated Expiration
- 2034-05-10
AI Technical Summary
When traditional laminated materials open air gaps in high-power inductors to reduce eddy current losses, the actual core loss is far beyond the theoretical value, and cut-out processing may lead to interlayer peeling and debris problems, increasing costs and noise.
The laminate winding loop combination design is adopted to form a closed loop through the combination of the middle column and the yoke, which avoids the opening of air gaps in the laminate material, and matches the yoke shape and size through the laminate winding loop combination to reduce empty space. Cavity size to improve filling rate.
It realizes avoiding air gaps in laminated materials, reducing core losses, simplifying the manufacturing process, reducing costs, and improving the fill rate and saturation resistance of the inductor.
Smart Images
Figure CN222530171U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a mixed material inductor prepared by using laminated strips. Background Art
[0002] In high-power inductors, traditional laminated materials such as amorphous nanocrystalline strips or silicon steel sheets are widely used due to their high magnetic permeability and high saturation magnetic induction intensity. After these materials are made into inductors, in order to ensure the required inductance under large currents, it is inevitable to set an air gap in the middle of the laminated materials, such as the common amorphous UU type inductor (such as Figure 1 The iron core 5 and winding 6 structure shown in the figure, as well as the structure shown in the circle), this will bring about the following problems:
[0003] 1. Since the magnetic permeability of laminated cores is much greater than that of air, the magnetic flux enters and exits the core vertically, which will generate large eddy current losses on the plane of the laminated core. Therefore, the air gap in the laminated core will greatly increase the core loss. When materials such as amorphous nanocrystalline are used with an air gap, the actual core loss will far exceed the theoretical value.
[0004] Second: When the laminated materials are cut, there may be problems such as interlayer peeling and inter-sheet adhesion caused by fragments that need to be overcome, resulting in the inability to effectively reduce costs.
[0005] Third, the cutouts destroy the integrity of the laminated core, which easily generates additional noise, which is often difficult to overcome. These are technical problems that need to be solved urgently.
[0006] Existing solutions such as Figure 2 As shown, the U-shaped closed winding loop (4a) is made of laminated material. Although the above-mentioned problem is solved, when the laminated material is made into a U-shaped closed winding loop, the volume of the opening-shaped cavity in the middle of the U-shaped closed winding loop (dimensions a*b*c) will affect the filling rate and glue injection amount of the actual product, and further affect the external dimensions and cost. Therefore, it is necessary to further optimize on this basis. Utility Model Content
[0007] In order to eliminate the gap, reduce the cavity size and improve the filling rate, the utility model provides an inductor. The technical solution of the utility model is as follows: there is at least one inductor unit, which is composed of a middle column, a coil wound thereon and two yokes respectively arranged at two ends of the middle column; the inductor units are arranged in a manner parallel to the axis of the middle column along the X direction; and a laminated winding loop combination is arranged on at least one side of each inductor unit, so that the side surfaces of the yokes at both ends of the inductor unit are tightly attached to the bottom surface of the laminated winding loop combination to form a closed loop; it is characterized in that: the laminated winding loop combination is composed of at least two groups of laminated winding loops arranged along the Z direction.
[0008] The laminate winding loop is formed by winding the laminate material from amorphous strips, nanocrystalline strips, or silicon steel strips into a closed magnetic core loop.
[0009] The material of the center column and the yoke is a magnetic powder core material, such as iron silicon magnetic powder core, sendust magnetic powder core, iron nickel magnetic powder core, etc.; the magnetic core materials of the center column and the yoke can be the same or different; in order to increase the anti-saturation ability of the inductor, the center column and the yoke can be provided with an air gap; the shapes of the center column and the yoke can be the same or different, for example, the shape of the upper and lower yokes can be square or runway-shaped, and it is only necessary to ensure that the yoke has a flat side that can be tightly attached to the bottom surface of the laminated winding loop combination, thereby eliminating the lack of air gap.
[0010] The beneficial effects of the utility model are as follows: the laminated winding loop adopts a combined design, which avoids opening an air gap in the laminated material, and the manufactured inductor device can withstand a large current, and the manufacturing is simple and the cost is low; and there is no air gap in the laminated material, and the core loss can be optimized; when the laminated winding loop combination matches the yoke iron outer dimensions, the cavity in the middle of the loop can be narrowed and elongated, the cavity size can be reduced, the filling rate can be increased, the volume can be reduced, the amount of glue injection can be reduced, and the cost advantage can be improved. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 , 2 It is a schematic diagram of the structure of an inductor in the prior art;
[0012] Figure 3 It is a schematic diagram of the structure decomposition of the utility model;
[0013] Figure 4 , 5 It is a schematic diagram of the structure of an embodiment of the utility model.
[0014] In the figure, 1: center column, 1a: center column axis, 2: coil, 3: yoke, 31: yoke side, 4: laminated winding circuit combination, 41: bottom surface, 4a: U-shaped closed winding circuit, 4b: laminated winding circuit, 5: iron core, 6: winding. DETAILED DESCRIPTION
[0015] like Figure 3As shown, the utility model has at least one inductor unit, which is composed of a middle column (1), a coil (2) wound thereon, and two yokes (3) respectively arranged at two ends of the middle column; the inductor units are arranged in a manner parallel to the middle column axis (1a) along the X direction; and a laminated winding loop assembly (4) is arranged on at least one side of each inductor unit, so that the yoke side surfaces (31) at two ends of the inductor unit are tightly attached to the bottom surface (41) of the laminated winding loop assembly (4) to form a closed loop; characterized in that: the laminated winding loop assembly (4) is composed of at least two groups of laminated winding loops (4b) arranged along the Z direction.
[0016] The utility model can realize two-way, three-way or multi-way parallel magnetic integrated inductance by connecting a plurality of inductance units in parallel and combining laminated winding loops.
[0017] The present invention will now be described in detail with reference to specific embodiments.
[0018] Embodiment 1:
[0019] like Figure 4 As shown, the inductor is formed by integrating three inductance units, and laminated winding loops (4b) are arranged at both ends of the arrangement so as to be closely attached to the yoke iron side surfaces (31) of the inductance units, thereby forming a three-way parallel magnetic integrated inductance.
[0020] When used as a three-phase inverter inductor, the wiring method is consistent with the traditional three-phase three-column or three-phase five-column. The high magnetic permeability of the laminated winding material determines that the coupling coefficient between the middle columns of each path is very low, and they can work independently of each other. The magnetic flux of the laminated winding material at the junction of the two adjacent middle columns is superimposed with a difference of 120°. When used as a DC boost inductor, the wiring direction of the middle path needs to be opposite to the wiring direction of the two sides, so that the magnetic flux generated by the coil current of each middle column will cancel each other out in the winding core at their junction, and the loss of the winding core at this location can also be reduced. When more integrated inductors are used as DC boost inductors, the wiring direction on each inductor needs to be opposite to the wiring direction of the inductor adjacent to the inductor. In addition, the gap in the middle of the laminated winding material group is long and narrow, and the filling rate is high.
[0021] Increasing the number of inductor units can form a multi-path parallel magnetic integrated inductor.
[0022] Embodiment 2:
[0023] like Figure 5 As shown, the inductor is integrated from two inductor units, and a laminated winding loop assembly 4 is arranged between the inductor units, thereby forming a two-way parallel magnetic integrated inductor.
[0024] The high magnetic permeability of the laminated winding material group in the middle determines that the coupling coefficient between the two middle columns is very low, and they can work independently of each other. When used as a DC boost inductor, the wiring directions of the two paths are opposite, and the magnetic flux generated by the coil currents of the two middle columns will cancel each other out in the winding core at their junction, which can reduce the loss of the winding core at this location. In addition, the gap in the middle of the laminated winding material group is long and narrow, and the filling rate is high.
[0025] The above-mentioned specific implementation methods are only exemplary and are intended to better enable those skilled in the art to understand this patent. They should not be understood as limiting the scope of this patent. Any changes or modifications that are essentially the same or equivalent to the technical content made according to the technical solution disclosed in this patent shall fall within the scope of this patent.
Claims
1. An inductor, comprising at least one inductor unit, the inductor unit comprising a central column (1), a coil (2) wound thereon, and two yokes (3) respectively arranged at two ends of the central column; the inductor units are arranged in a manner parallel to the central column axis (1a) along the X direction; and a laminated winding loop assembly (4) is arranged on at least one side surface of each inductor unit, so that the yoke side surfaces (31) at two ends of the inductor unit are in close contact with the bottom surface (41) of the laminated winding loop assembly (4) to form a closed loop; characterized in that: The laminate winding loop combination (4) is composed of at least two groups of laminate winding loops (4b) arranged along the Z direction.
2. The inductor according to claim 1, wherein: The number of inductance units arranged is three, and laminated winding loops (4b) are arranged at both ends of the arrangement so as to be closely attached to the yoke iron side surfaces (31) of the inductance units.
3. The inductor according to claim 1, wherein: The number of arranged inductance units is two, and a laminated winding loop assembly (4) is arranged between the inductance units.