Inductor structure

Abstract

The utility model discloses an inductor structure, and belongs to the technical field of new energy. The inductor structure comprises a shell, a magnetic core assembly and a second potting part, the magnetic core assembly is vertically placed in the shell and comprises an annular magnetic core and a winding, a through hole is formed in the annular magnetic core, the winding penetrates through the through hole and is wound around the annular magnetic core, a first potting part is formed in the through hole in a potting mode, and the second potting part is formed between the shell and the magnetic core assembly in a potting mode. The encapsulating material of the first encapsulating part is different from the encapsulating material of the second encapsulating part, so that the inductance structure can generate heat in the working process, and different materials have different thermal expansion coefficients. By using the encapsulating materials with different thermal expansion coefficients, thermal stress caused by temperature change can be relieved to a certain extent, so that the risk of cracking of the annular magnetic core is reduced.

Description

Technical Field

[0001] The present application belongs to the field of new energy technology, and in particular relates to an inductor structure. Background Art

[0002] In order to increase the power density of the charging module and reduce the volume of the charging module, the inductor core is usually installed vertically, which can effectively reduce the plane area of ​​the core and make full use of the space. However, the vertically installed PFC toroidal inductor core is potted with high-hardness epoxy resin potting glue. When the inductor is working, high temperature is generated. The epoxy resin potting glue expands due to heat, and then produces expansion and squeezing force on the core, causing structural stress on the core device. When the structural stress exceeds the strength of the core material, the core will crack. Utility Model Content

[0003] The present application aims to solve at least one of the technical problems existing in the prior art. To this end, the present application proposes an inductor structure, which aims to solve the problem that the magnetic core of the PFC toroidal inductor structure in the prior art is prone to cracking after being glued.

[0004] In a first aspect, the present application provides an inductor structure, comprising:

[0005] case;

[0006] A magnetic core assembly is placed vertically in the shell, the magnetic core assembly includes an annular magnetic core and a winding, the annular magnetic core is formed with a through hole, the winding passes through the through hole and is wound around the annular magnetic core, and a first potting portion is formed by potting in the through hole;

[0007] A second potting part is formed by potting between the shell and the magnetic core component; wherein the potting material of the first potting part is different from the potting material of the second potting part.

[0008] According to the inductor structure of the present application, since the winding is directly wound on the annular magnetic core and the through hole is filled with the first potting part, the heat of the winding can be conducted to the housing through the first potting part more quickly, thereby improving the overall heat dissipation efficiency and ensuring that the inductor can maintain a stable temperature when it is under high load or working for a long time. The first potting part formed by potting not only provides electrical insulation, but also plays a role in fixing the winding, preventing the displacement or vibration of the winding during operation, and enhancing the stability of the inductor structure. The second potting part, as a medium for heat conduction, can quickly and effectively transfer the heat generated by the magnetic core assembly to the housing. This efficient heat conduction helps to reduce the temperature rise of the inductor during operation, ensure that the inductor can work stably in a high temperature environment, and extend its service life. The second potting part not only plays a role in heat conduction, but also can enhance the structural connection between the housing and the magnetic core assembly. The second potting part formed by potting can tightly combine the two together, reduce looseness or displacement caused by vibration or impact, and improve the overall strength and stability of the inductor structure. As an insulating material, the second potting part can effectively isolate the electrical connection between the shell and the magnetic core assembly to prevent safety hazards caused by short circuit or leakage. The first potting part is formed by potting in the through hole, and the second potting part is formed by potting between the shell and the magnetic core assembly. The potting material of the first potting part is different from the potting material of the second potting part. Since the inductor structure generates heat during operation, different materials have different thermal expansion coefficients. By using potting materials with different thermal expansion coefficients, the thermal stress caused by temperature changes can be alleviated to a certain extent, thereby reducing the risk of cracking of the annular magnetic core.

[0009] According to an embodiment of the present application, the hardness of the potting material of the first potting part is greater than the hardness of the potting material of the second potting part.

[0010] According to an embodiment of the present application, the encapsulation material of the first encapsulation part is associated with the aperture of the through hole;

[0011] Alternatively, the potting material of the first potting part is associated with the material of which the annular magnetic core is made.

[0012] According to an embodiment of the present application, the hardness of the potting material of the first potting part is inversely proportional to the aperture of the through hole;

[0013] Alternatively, the hardness of the potting material of the first potting part is proportional to the strength of the annular magnetic core.

[0014] According to one embodiment of the present application, the thickness of the first potting portion is greater than or equal to the thickness of the annular magnetic core after winding the winding.

[0015] According to an embodiment of the present application, the potting material of the first potting part includes at least one of silicone gel, soft polyurethane and flexible epoxy resin;

[0016] The potting material of the second potting part includes at least one of epoxy resin and silicone.

[0017] According to one embodiment of the present application, it also includes:

[0018] An insulating mounting frame is fixedly arranged on the shell, and the insulating mounting frame has a mounting portion located in the shell, and the mounting portion is used to place the magnetic core component so that there is a gap between the magnetic core component and the shell.

[0019] According to one embodiment of the present application, a distance between an outer wall surface of the magnetic core component and an inner wall surface of the shell is L, wherein L≥3 mm.

[0020] According to an embodiment of the present application, a plurality of the magnetic core components are provided, and the plurality of the magnetic core components are arranged at intervals in the shell.

[0021] According to one embodiment of the present application, the annular magnetic core includes at least two magnetic core bodies arranged side by side along its thickness direction, a mounting hole is penetrated through the middle of each of the magnetic core bodies, and the mounting holes of the at least two magnetic core bodies are coaxially arranged to form the through hole.

[0022] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become apparent from the description below, or will be learned through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0024] Figure 1 It is one of the structural schematic diagrams of the inductor structure provided in the embodiment of the present application;

[0025] Figure 2 yes Figure 1 A schematic diagram of the structure of the middle magnetic core component and the second potting part;

[0026] Figure 3 yes Figure 1 A schematic diagram of the structure of the middle insulation mounting frame and the magnetic core assembly (first angle);

[0027] Figure 4 yes Figure 1 A schematic diagram of the structure of the middle insulation mounting frame and the magnetic core assembly (second angle);

[0028] Figure 5 yes Figure 1 Structural schematic diagram of the middle insulation mounting frame and magnetic core assembly (third angle);

[0029] Figure 6 yes Figure 5 Schematic diagram of the relationship between the thickness of the first potting part and the thickness of the annular magnetic core after winding.

[0030] Reference numerals:

[0031] Inductor structure 100;

[0032] Housing 110, heat dissipation fins 111;

[0033] A magnetic core assembly 120, a ring-shaped magnetic core 121, a magnetic core body 1211, a through hole 1212, a winding 122, and a first potting portion 123;

[0034] A second potting portion 130;

[0035] Insulating mounting frame 140 and mounting portion 141 . DETAILED DESCRIPTION

[0036] The embodiments of the present application 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 only used to explain the present application, and cannot be understood as limiting the present application.

[0037] Reference below Figure 1-Figure 6 An inductor structure according to an embodiment of the present application is described.

[0038] Reference Figures 1 to 3 The inductor structure 100 includes a housing 110 , a magnetic core component 120 and a second potting portion 130 .

[0039] The shell 110 has various shapes. For example, the shell 110 can be rectangular, cube-shaped or cylindrical, etc. Specifically, the present application does not limit this. In addition, the shell 110 can be made of metal, plastic, etc. The material of the shell 110 can be selected according to actual needs.

[0040] The magnetic core assembly 120 is placed vertically in the shell 110, and the magnetic core assembly 120 includes an annular magnetic core 121 and a winding 122. The annular magnetic core 121 is formed with a through hole 1212. The winding 122 passes through the through hole 1212 and is wound around the annular magnetic core 121. A first potting portion 123 is formed by potting in the through hole 1212. Specifically, the through hole 1212 can be cylindrical or prismatic, and the present application does not limit this.

[0041] The second potting part 130 is formed by potting between the housing 110 and the magnetic core assembly 120 , and the potting material of the first potting part 123 is different from the potting material of the second potting part 130 .

[0042] It should be noted that the potting material of the first potting part 123 is different from the potting material of the second potting part 130, which will cause the strength, hardness, expansion force, thermal conductivity and insulation of the first potting part 123 to be different from the strength, hardness, expansion force, thermal conductivity and insulation of the second potting part 130.

[0043] According to the inductor structure 100 of the present application, since the winding 122 is directly wound on the annular magnetic core 121, and the through hole 1212 is filled with the first potting part 123, the heat of the winding 122 can be more quickly transferred to the housing 110 through the first potting part 123, thereby improving the overall heat dissipation efficiency and ensuring that the inductor can maintain a stable temperature when it is under high load or working for a long time. The first potting part 123 formed by potting not only provides electrical insulation, but also plays a role in fixing the winding 122, preventing the displacement or vibration of the winding 122 during operation, and enhancing the stability of the inductor structure 100. The second potting part 130, as a medium for heat conduction, can quickly and effectively transfer the heat generated by the magnetic core assembly 120 to the housing 110. This efficient heat conduction helps to reduce the temperature rise of the inductor during operation, ensure that the inductor can work stably in a high temperature environment, and extend its service life. The second potting part 130 not only plays a role in heat conduction, but also can enhance the structural connection between the housing 110 and the magnetic core assembly 120. The second potting part 130 formed by potting can tightly combine the two together, reduce looseness or displacement caused by vibration or impact, and improve the overall strength and stability of the inductor structure 100. As an insulating material, the second potting part 130 can effectively isolate the electrical connection between the housing 110 and the magnetic core assembly 120, and prevent safety hazards caused by short circuits or leakage. The first potting part 123 is formed by potting in the through hole 1212, and the second potting part 130 is formed by potting between the housing 110 and the magnetic core assembly 120. The potting material of the first potting part 123 is different from the potting material of the second potting part 130. Since the inductor structure generates heat during operation, different materials have different thermal expansion coefficients. By using potting materials with different thermal expansion coefficients, the thermal stress caused by temperature changes can be alleviated to a certain extent, thereby reducing the risk of cracking of the annular core 121.

[0044] In one embodiment, the hardness of the potting material of the first potting part 123 is less than the hardness of the potting material of the second potting part 130, which means that the deformation ability and buffering effect of the first potting part 123 are better than those of the second potting part 130. During the operation of the inductor, due to the change of current and the action of electromagnetic force, the annular magnetic core 121 and the winding 122 may be subjected to certain vibrations and impacts. The first potting part 123 with better deformation ability can better absorb these vibrations and impacts, reduce the stress on the annular magnetic core 121, and thus effectively prevent the annular magnetic core 121 from cracking. The soft-hard combination design of the first potting part 123 and the second potting part 130 can also balance the rigidity and toughness of the inductor structure 100 to a certain extent. The second potting part 130 has a higher hardness, which provides the necessary support and stability for the inductor structure 100, and prevents the inductor structure 100 from being deformed or broken under the action of external forces. In addition, the second potting part 130 can not only prevent the inductor from being deformed or displaced when heated, but also ensure the tight connection between the housing 110 and the magnetic core assembly 120, reducing the decrease in heat conduction efficiency caused by looseness or gaps. This helps to maintain the stable operation of the inductor in a high temperature environment and further reduce the risk of the annular magnetic core 121 being cracked due to heat.

[0045] In addition, when the inductor is working, especially under high load or high temperature environment, a large amount of heat will be generated inside it. The first potting part 123 serves as a heat conduction medium between the winding 122 and the annular core 121. Its smaller hardness means that it has better deformation ability and filling performance, which enables the first potting part 123 to better fill the small gap between the winding 122 and the annular core 121, reduce thermal resistance, and improve heat conduction efficiency. Therefore, heat can be transferred to the housing 110 more quickly through the first potting part 123, thereby reducing the temperature of the annular core 121. Secondly, the softer hardness of the first potting part 123 also means that it has a certain elasticity and buffering effect. When the inductor expands due to heat, the softer first potting part 123 can absorb part of the expansion force and reduce the direct extrusion of the annular core 121. This helps to reduce the stress concentration of the annular core 121 caused by thermal expansion, and further reduces the possibility of cracking of the annular core 121.

[0046] Specifically, in one embodiment, the hardness of the first potting part 123 is A1, and the hardness of the second potting part 130 is A2, wherein A1=A2 / 500. Of course, in other embodiments, the hardness relationship between the first potting part 123 and the second potting part 130 can be set as needed, and this application does not limit this.

[0047] For the annular magnetic core 121 with different apertures of the through hole 1212, the properties of the potting material of the first potting part 123 potted in the through hole 1212 are also different. The larger the aperture of the through hole 1212, the larger the volume inside the through hole 1212. If you want to reduce the expansion force of the first potting part 123, you need to reduce the hardness of the potting material of the first potting part 123. Specifically, in one embodiment, the potting material of the first potting part 123 is associated with the aperture of the through hole 1212. In this way, the potting material of the first potting part 123 is associated with the aperture of the through hole 1212, so that the connection between the potting material of the first potting part 123 and the aperture of the through hole 1212 is established, which facilitates the selection of a suitable potting material of the first potting part 123 according to the size of the aperture, ensuring that the first potting part 123 has a suitable expansion force, which helps to reduce the thermal stress caused by temperature changes, thereby reducing the risk of cracking of the annular magnetic core 121. By selecting a suitable potting material according to the aperture of the through hole 1212, it can be ensured that the heat generated by the winding 122 can be effectively dissipated. This helps to reduce the operating temperature of the inductor structure 100 and improve its reliability and service life. Meanwhile, during maintenance, if the potting material of the first potting part 123 needs to be replaced or repaired, a suitable potting material can be selected according to the aperture of the through hole 1212, thereby simplifying the maintenance process.

[0048] Specifically, the hardness of the potting material of the first potting part 123 is inversely proportional to the aperture of the through hole 1212, that is, as the aperture of the through hole 1212 increases, the hardness of the potting material of the first potting part 123 will decrease. Exemplarily, in one embodiment, for an annular magnetic material with an aperture of 26 mm in the through hole 1212, the first potting part 123 may be made of soft polyurethane, whose material hardness is about Shore A 20, and the second potting part 130 may be made of epoxy resin, whose material hardness is about Shore A 45. For an annular magnetic material with an aperture of 28 mm in the through hole 1212, the first potting part 123 may be made of silicone gel, whose material hardness is about Shore A 10, and the Shore A 20 hardness is greater than the Shore A 10 hardness. It should be noted that, in other embodiments, the hardness of the potting material of the first potting part 123 and the aperture of the through hole 1212 can be selected as needed, and the present application does not limit this.

[0049] For different types of annular magnetic cores 121, the strength of the annular magnetic cores 121 also varies. Different annular magnetic cores 121 are selected, and the hardness of the filling material of the through hole 1212 is also different. In one embodiment, the potting material of the first potting part 123 is associated with the material of the annular magnetic core 121. In this way, the thermal stress or mechanical stress caused by material differences can be reduced, thereby enhancing the stability and reliability of the inductor structure 100. By optimizing the combination of the potting material of the first potting part 123 and the material of the annular magnetic core 121, the first potting part 123 can better adapt to the strength characteristics of the annular magnetic core 121, reducing the stress concentration or performance degradation caused by material mismatch. The hardness of the potting material of the first potting part 123 directly affects its thermal conductivity. By adjusting the hardness of the potting material of the first potting part 123, the thermal conductivity efficiency of the first potting part 123 can be optimized to ensure that heat can be more effectively transferred from the annular core 121 to the heat dissipation structure, which helps to improve the heat dissipation capacity of the inductor structure 100 under high load or high temperature environment and maintain its stable operation.

[0050] Specifically, the hardness of the potting material of the first potting part 123 is proportional to the strength of the annular magnetic core 121, that is, as the hardness of the potting material of the first potting part 123 increases, the strength of the annular magnetic core 121 will increase. Exemplarily, in one embodiment, for an organic silicone gel with a hardness of about shore o 10 of the potting material of the first potting part 123, the tensile strength of the annular magnetic core 121 is 4000N / cm 2 The potting material of the first potting part 123 is soft polyurethane with a hardness of about shore o 20, and the strength of the annular magnetic core 121 is 5000N / cm 2 It should be noted that, in other embodiments, the hardness of the potting material of the first potting portion 123 and the strength of the annular magnetic core 121 can be selected as needed, and the present application does not limit this.

[0051] In one embodiment, the thickness of the first encapsulation portion 123 is greater than or equal to the thickness of the annular magnetic core 121 after the winding 122 is wound. Figure 6 As shown, the thickness of the annular magnetic core 121 is h m , it is assumed that along the thickness direction of the annular core 121, the thickness of the winding 122 stacked on one side of the annular core 121 is h l , the thickness of the first encapsulation portion 123 is H1, wherein H1≥h m +2h l. When the thickness of the first potting part 123 is greater than or equal to the thickness of the annular magnetic core 121 after the winding 122 is wound, it means that the first potting part 123 has a larger surface area, which helps the inductor structure 100 to dissipate heat more effectively. The inductor structure 100 generates heat during operation, and good heat dissipation can ensure that the inductor structure 100 maintains a stable temperature during continuous operation to avoid performance degradation or damage caused by overheating. When the thickness of the first potting part 123 is greater than or equal to the thickness of the annular magnetic core 121 after the winding 122 is wound, the first potting part 123 can more effectively isolate and reduce the electromagnetic interference (EMI) generated by the inductor structure 100, and can also enhance the insulation performance inside the inductor structure 100. In addition, the thickness of the first potting part 123 is greater than or equal to the thickness of the annular magnetic core 121 after the winding 122 is wound, so that the first potting part 123 can also be used as an auxiliary means for assembly or positioning. For example, the first potting portion 123 can provide stable support for the inductor structure 100 , helping it to be correctly positioned and fixed inside the housing 110 .

[0052] In one embodiment, the material of the first potting part 123 has the characteristics of extremely low hardness, low expansion rate, and high thermal conductivity. For example, the material of the first potting part 123 includes at least one of silicone gel, soft polyurethane and flexible epoxy resin. In this way, the first potting part 123 has excellent electrical insulation performance, can withstand voltage and corona, and has a high flame retardant level, ensuring that the first potting part 123 can also work stably in harsh environments such as high voltage and sunlight, effectively isolating and preventing current leakage or short circuit, and improving the safety and reliability of the overall circuit. The first potting part 123 works under high temperature and will not easily break or decompose. This characteristic enables the first potting part 123 to maintain stable performance in a wide temperature range, and its insulation effect will not be affected by temperature changes.

[0053] It should be noted that, in the embodiment of the present application, the material of the first potting part 123 is selected from organic silicone gel, so that the potting stress of the first potting part 123 on the through hole position is minimized. In addition, organic silicone gel has extremely low hardness, extremely low temperature rise expansion force, and has good thermal conductivity and insulation. Of course, in other embodiments, the material of the first potting part 123 can be selected as needed.

[0054] In one embodiment, the material of the second potting part 130 has the characteristics of high hardness, low expansion rate, high thermal conductivity, etc. For example, the material of the second potting part 130 includes at least one of epoxy resin and silicone. In this way, the second potting part 130 has high hardness, is not easy to deform and bulge, has good sealing performance, and has low cost.

[0055] It should be noted that, in the embodiment of the present application, epoxy resin is selected as the material of the second potting portion 130. Of course, in other embodiments, the material of the second potting portion can be selected as needed.

[0056] In one embodiment, the inductor structure 100 further includes an insulating mounting frame 140, which is fixedly disposed on the housing 110. The insulating mounting frame 140 has a mounting portion 141 in the housing 110, and the mounting portion 141 is used to place the magnetic core component 120, so that there is a gap between the outer wall surface of the magnetic core component 120 and the inner wall surface of the housing 110. In this way, one of the main functions of the insulating mounting frame 140 is to provide electrical isolation to ensure that there is no unexpected electrical contact between the magnetic core component 120 and the housing 110. This design helps to prevent short circuits and electrical failures, thereby improving the overall safety and reliability of the inductor structure 100. The insulating mounting frame 140 keeps a gap between the outer wall surface of the magnetic core component 120 and the inner wall surface of the housing 110, and this design helps to form a heat dissipation channel and improve the heat dissipation efficiency. Heat can be more smoothly conducted from the magnetic core component 120 to the housing 110, and dissipated to the outside through the housing 110, thereby ensuring that the inductor structure 100 can maintain stable performance even under high load or high temperature environments. The insulating mounting frame 140 is fixed to the housing 110, providing a stable mounting platform for the magnetic core assembly 120. This makes the installation process of the magnetic core assembly 120 easier and faster, reducing the installation difficulty and cost. The insulating mounting frame 140 not only fixes the magnetic core assembly 120, but also enhances the overall stability of the inductor structure 100. It can prevent the magnetic core assembly 120 from shifting or loosening under vibration or impact, thereby ensuring the long-term stable operation of the inductor structure 100.

[0057] It should be noted that the material of the insulating mounting frame 140 has the characteristics of high temperature resistance, fire resistance and not easy to deform. Specifically, the material of the insulating mounting frame 140 can include at least one of ceramic material, polymer material, glass fiber and resin composite material, engineering plastic and polycarbonate. Ceramic is a traditional insulating material with the characteristics of high temperature resistance, chemical corrosion resistance and high hardness. In particular, ceramic materials such as alumina and silicon nitride not only have excellent insulation properties, but also can meet the use requirements of special occasions. Polymer materials These materials usually have the advantages of light weight, high temperature resistance, flame retardancy and good insulation. High-performance polymer materials such as polyimide and polystyrene are suitable for inductor brackets in high temperature, high pressure and strong corrosive environments. Glass fiber and resin composite materials are made by high temperature polymerization and pultrusion process, have good structural mechanical properties and bending strength, and have the characteristics of corrosion resistance, aging resistance and convenience of use. The components such as epoxy resin and urea-formaldehyde resin provide excellent insulation performance and high temperature resistance for the insulating mounting frame 140. Engineering plastics and polycarbonate have excellent properties such as compression resistance, tensile resistance, wear resistance, aging resistance, and corrosion resistance, and are very suitable as the material for the insulating mounting frame 140 .

[0058] In addition, there are many ways to fix the insulating mounting frame 140 to the housing 110. For example, the insulating mounting frame 140 can be fixed to the housing 110 by screwing. In one embodiment, the insulating mounting frame 140 can be welded and fixed to the housing 110. Of course, in other embodiments, the insulating mounting frame 140 can be fixed to the housing 110 by a binding band, etc. Specifically, this application does not limit this.

[0059] Specifically, in one embodiment, the distance between the outer wall surface of the magnetic core component 120 and the inner wall surface of the housing 110 is L, where L≥3mm. In this way, there is sufficient distance between the outer wall surface of the magnetic core component 120 and the inner wall surface of the housing 110, which can not only reduce thermal resistance, but also improve the overall heat dissipation efficiency, ensuring that the inductor can maintain stable performance under high load or high temperature environment. A larger distance L can reduce the thermal stress between the magnetic core component 120 and the housing 110 due to temperature changes. When the inductor is working, the magnetic core component 120 may generate heat, and the housing 110 plays a role in heat dissipation. If the distance is too small, thermal expansion may cause stress concentration between the two, thereby affecting the structural stability and long-term reliability of the inductor structure. By ensuring that the distance L≥3mm, these thermal stresses can be effectively dispersed and reduced. Sufficient distance L also facilitates the manufacture and assembly of the inductor structure 100. During the manufacturing process, a larger distance can reduce the high requirements for precision and reduce the manufacturing difficulty and cost. At the same time, during the assembly process, a larger spacing is also more conducive to installing and adjusting the position of the magnetic core assembly 120, thereby improving assembly efficiency.

[0060] Reference Figure 1 , Figure 3 and Figure 4 In one embodiment, a plurality of magnetic core components 120 are provided, and the plurality of magnetic core components 120 are arranged at intervals in the housing 110. Thus, by adopting a plurality of magnetic core components 120, the magnetic flux of the inductor structure 100 can be increased, thereby improving the inductance value and current handling capacity of the inductor structure. This design enables the inductor to better adapt to the working environment of high current and high frequency, and improves the overall performance. The plurality of magnetic core components 120 are arranged at intervals in the housing 110, which helps to form a more uniform heat dissipation channel. Heat can be more effectively transferred from each magnetic core component 120 to the housing 110, and dissipated to the environment through the surface area of ​​the housing 110. This design can reduce heat accumulation and reduce temperature rise, thereby ensuring that the inductor can maintain stable performance under long-term operation. The spaced magnetic core components 120 can reduce stress concentration caused by thermal expansion. Each magnetic core component 120 has enough space for thermal expansion without interfering with each other or generating excessive stress.

[0061] Reference Figure 1 In the embodiment of the present application, a plurality of magnetic core components 120 are arranged side by side along the length direction of the shell. Thus, due to the side-by-side arrangement of the magnetic core components 120, the magnetic flux of the entire inductor structure 100 can be significantly increased. The side-by-side arrangement of the plurality of magnetic core components 120 helps to improve the uniformity of the magnetic field. When the magnetic core components 120 are evenly distributed, the magnetic fields they generate will overlap with each other, thereby forming a more uniform magnetic field distribution inside the entire inductor structure 100.

[0062] Reference Figure 5In one embodiment, the annular magnetic core 121 includes at least two magnetic core bodies 1211 arranged side by side along the thickness direction thereof, and a mounting hole is provided in the middle of each magnetic core body 1211, and the mounting holes of at least two magnetic core bodies 1211 are coaxially arranged to form a through hole 1212. In this way, by arranging multiple magnetic core bodies 1211 side by side, the magnetic flux of the annular magnetic core 121 can be significantly increased. The increase in magnetic flux means that the inductor structure 100 can store and transmit magnetic energy more effectively, thereby improving its inductance value and current handling capacity. The side-by-side design of multiple magnetic core bodies 1211 can increase the heat dissipation area and make the heat more evenly distributed on the entire annular magnetic core 121. This helps to reduce the temperature rise generated by the annular magnetic core 121 during operation and improve the stability and reliability of the inductor structure 100. Since the mounting holes of each magnetic core body 1211 are coaxially arranged, it can be easily installed and disassembled through the through hole 1212. This design makes the assembly and maintenance of the inductor structure 100 simpler and faster, and improves work efficiency. By arranging a plurality of magnetic core bodies 1211 side by side, the stress and deformation generated by the annular magnetic core 121 during operation can be dispersed, thereby improving the stability and reliability of the overall structure.

[0063] Reference Figure 1 In one embodiment, the outer wall surface of the housing 110 is provided with a plurality of heat dissipation fins 111, and the plurality of heat dissipation fins 111 are arranged at intervals, so that the heat dissipation fins 111 can increase the surface area of ​​the housing 110, thereby expanding the heat exchange area with the surrounding environment. When the device is running, the generated heat can be more effectively dissipated into the air through the heat dissipation fins 111, thereby reducing the temperature of the housing 110, thereby ensuring the normal operation of the magnetic core assembly 120 inside the housing 110. The plurality of heat dissipation fins 111 are arranged at intervals, which not only provides a larger heat dissipation area, but also reduces the resistance of air flow, allowing air to flow more smoothly through the heat dissipation fins 111, thereby improving the heat dissipation efficiency. The heat dissipation fins 111 not only have a heat dissipation function, but also can enhance the structural strength of the housing 110 to a certain extent. They can serve as a supporting structure to increase the impact and pressure resistance of the housing 110 and improve the stability of the overall structure.

[0064] In addition, in order to improve the heat dissipation effect of the shell 110, the material of the shell 110 can also include aluminum, aluminum alloy or carbon fiber composite material. Specifically, this application does not limit this.

[0065] The terms "first", "second", etc. in the specification and claims of the present application are used to distinguish similar objects, and are not used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable under appropriate circumstances, so that the embodiments of the present application can be implemented in an order other than those illustrated or described here, and the objects distinguished by "first", "second", etc. are generally of one type, and the number of objects is not limited. For example, the first object can be one or more. In addition, "and / or" in the specification and claims represents at least one of the connected objects, and the character " / " generally indicates that the objects associated with each other are in an "or" relationship.

[0066] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0067] In the description of this application, "first feature" or "second feature" may include one or more of the features.

[0068] In the description of the present application, “plurality” means two or more.

[0069] In the description of the present application, a first feature being “on” or “under” a second feature may include that the first and second features are directly in contact with each other, or may include that the first and second features are not in direct contact with each other but are in contact with each other via another feature therebetween.

[0070] In the description of the present application, “above”, “over” and “above” a first feature to a second feature includes the first feature being directly above and obliquely above the second feature, or simply means that the first feature is horizontally higher than the second feature.

[0071] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0072] Although the embodiments of the present application have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present application, and that the scope of the present application is defined by the claims and their equivalents.

Claims

1. An inductor structure, characterized in that: include: case; A magnetic core assembly is placed vertically in the shell, the magnetic core assembly includes an annular magnetic core and a winding, the annular magnetic core is formed with a through hole, the winding passes through the through hole and is wound around the annular magnetic core, and a first potting portion is formed by potting in the through hole; A second potting part is formed by potting between the shell and the magnetic core component; wherein the potting material of the first potting part is different from the potting material of the second potting part.

2. The inductor structure according to claim 1, characterized in that: The hardness of the potting material of the first potting part is smaller than the hardness of the potting material of the second potting part.

3. The inductor structure according to claim 1, characterized in that: The encapsulation material of the first encapsulation part is associated with the aperture of the through hole; Alternatively, the potting material of the first potting part is associated with the material of which the annular magnetic core is made.

4. The inductor structure according to claim 3, characterized in that: The hardness of the potting material of the first potting part is inversely proportional to the aperture of the through hole; Alternatively, the hardness of the potting material of the first potting part is proportional to the strength of the annular magnetic core.

5. The inductor structure according to claim 1, characterized in that: The thickness of the first potting portion is greater than or equal to the thickness of the annular magnetic core after winding the winding.

6. The inductor structure according to any one of claims 1 to 5, characterized in that: The potting material of the first potting part includes at least one of silicone gel, soft polyurethane and flexible epoxy resin; The potting material of the second potting part includes at least one of epoxy resin and silicone.

7. The inductor structure according to any one of claims 1 to 5, characterized in that: Also includes: An insulating mounting frame is fixedly arranged on the shell, and the insulating mounting frame has a mounting portion located in the shell, and the mounting portion is used to place the magnetic core component so that there is a gap between the magnetic core component and the shell.

8. The inductor structure according to claim 7, characterized in that: The distance between the outer wall surface of the magnetic core component and the inner wall surface of the shell is L, wherein L≥3mm.

9. The inductor structure according to any one of claims 1 to 5, characterized in that: A plurality of magnetic core components are provided, and the plurality of magnetic core components are arranged at intervals in the shell.

10. The inductor structure according to any one of claims 1 to 5, characterized in that: The annular magnetic core comprises at least two magnetic core bodies arranged side by side along the thickness direction thereof, a mounting hole is penetrated through the middle of each of the magnetic core bodies, and the mounting holes of the at least two magnetic core bodies are coaxially arranged to form the through hole.

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