Power inductor for high-power photovoltaic energy storage

Abstract

The utility model discloses a power inductor for high-power photovoltaic energy storage, which comprises an inductor box and an inverter casing, the inductor box and the inverter casing are fixedly mounted after being positioned by a boss, a sealing groove is arranged on a contact surface where the inductor box and the inverter casing are mounted, and the inverter casing is hermetically mounted in the sealing groove through a sealing rubber strip. The inductor assembly is placed in the inner cavity in an attached mode, and heat conduction silica gel is filled in a gap between the inductor assembly and the inner cavity, so that the inductor power density and the heat dissipation efficiency are improved, the product size is reduced, installation and disassembly are convenient, and cost is reduced. And the whole structure adopts a scheme of bending the lead, punching the flat wire and matching with flange nut connection. The partition plate is designed to be of a buckle boss structure to isolate the inductor and the inductor box, a certain insulation distance is guaranteed, and the insulation effect is achieved. Heat can be quickly transmitted to the inductor box through the heat-conducting glue, temperature rise is reduced, and working efficiency is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of high-power inductors, and in particular to a power inductor used for high-power photovoltaic energy storage. Background Art

[0002] Inductors, also known as reactors and chokes, are components that can convert electrical energy into magnetic energy based on the principle of electromagnetic induction. In AC circuits, they have the ability to block the passage of current and are often used for current blocking, voltage conversion, AC coupling, and loads. Power inductors are important components of photovoltaic inverters and AC energy storage devices. They mainly play the role of filtering, energy storage, and circuit protection. In conjunction with related electronic devices, they can achieve the purpose of converting DC into AC.

[0003] With the development of photovoltaic inverters / energy storage devices with high power, high efficiency, high power density and high integration, the internal electronic devices have also developed accordingly, and higher requirements have been put forward for the design of power inductors. Reducing the size of power inductors to achieve higher power density, reduce temperature rise, reduce losses, improve work efficiency, facilitate product installation and disassembly, and reduce costs are all the goals of current power inductor design and the problems to be solved by the present invention.

[0004] At the same time, the traditional power inductor and the inductor box are insulated and protected by laying a layer of insulating film. Although this insulating film can achieve the purpose of insulation, it will greatly reduce the heat dissipation effect. The polyester film is between the inductor and the inductor box, resulting in the thermal conductive adhesive failing to directly connect the inductor and the inductor box through thermal conductivity. When the internal heat is dissipated, it needs to be conducted to the polyester film, then to the thermal conductive adhesive, and finally to the inductor box through the thermal conductive adhesive. Since the thermal conductivity of the polyester film is very low, only 0.2W / m·K, and the thermal conductivity of the thermal conductive silicone is 1.5W / m·K, the thermal conductivity effect is nearly 7 times different. Therefore, the heat dissipation effect of the product is greatly reduced. The block inductor partition designed in the present invention can solve this problem.

[0005] Therefore, it is necessary to provide a power inductor for high-power photovoltaic energy storage. Utility Model Content

[0006] In view of the problems existing in the above-mentioned prior art, the utility model provides a power inductor for high-power photovoltaic energy storage, the purpose of which is to solve the above-mentioned technical problems.

[0007] In order to achieve the above-mentioned purpose, the utility model is implemented through the following technical solutions: a power inductor for high-power photovoltaic energy storage, including an inductor box that is positioned with an inverter casing by a boss and then fixedly installed with the inverter casing, a sealing groove is provided on the contact surface where the inductor box and the inverter casing are installed, the sealing groove is sealed with the inverter casing by a sealing strip, two inner cavities are opened inside the inductor box, the two inner cavities are separated by a central partition, the groove opened inside the inner cavity is opened by profiling the shape of the inductor component, the inductor component is placed in the inner cavity, and thermal conductive silica gel is poured into the gap between the inductor component and the inner cavity. The heat dissipation of the inductor component is transferred to the inductor box through the heat transfer and conductivity characteristics of the thermally conductive silicone. The inductor component includes a dual-axis magnetic core. The two sides of the dual-axis magnetic core are correspondingly sleeved as limit partitions 1 and 2. Limit partitions 1 and 2 are used to limit the flat wire coil wound on the magnetic core, and through the installation of limit partitions 1 and 2, the magnetic core and the inductor box are separated and do not contact each other. The connector end of the flat wire coil is located on the limit partition 2, and a support frame for locking the connector end is clamped and installed on the limit partition 2. The support frame is fixedly installed with the inverter terminal by setting a flange nut inside, so as to fix the inverter terminal and the connector end.

[0008] Preferably, both the first and second limit partitions include a limit partition that is sleeved with the dual-axis magnetic core, a surface of the limit partition close to the flat wire coil is set as a limit platform, the limit platform is set in contact with the end of the flat wire coil to separate the flat wire coil from the inductor box, a surface of the limit partition away from the flat wire coil is set as a baffle, the baffle is evenly provided with hooks in the circumferential direction, the hooks are engaged with the end face of the dual-axis magnetic core, the end face of the hook away from the baffle protrudes from the end face of the dual-axis magnetic core, so as to separate the dual-axis magnetic core from the inductor box without contact through the protruding end face of the hook.

[0009] Preferably, a fixing frame is provided on the upper part of the limiting partition on the limiting partition two, and the fixing frame is provided with a wiring slot one matching with the joint end, and a positioning slot and a slot two are correspondingly provided on both sides of the wiring slot one, and a matching positioning slot at the end of the support frame is provided with a positioning rib, and a buckle part is provided to match the slot two, and the positioning rib is positioned and installed with the positioning slot, and the buckle part is clamped with the slot two, so that the support frame is fixedly installed on the fixing frame.

[0010] Preferably, the middle portion of the support frame is set as a hexagonal groove, a flange nut is placed inside the hexagonal groove, the joint end is bent to contact the flange nut, and the joint end is provided with a hexagonal groove 2 coaxial with the flange nut, the inverter terminal passes through the hexagonal groove 2 and is installed with the hexagonal groove thread to fix the inverter terminal and the joint end.

[0011] Preferably, the butt joint surface between the limiting partition and the flat wire coil is sealed by glue.

[0012] Preferably, a mounting hole is provided in the circumferential direction of the mating surface where the inductance box and the inverter housing are mounted.

[0013] Preferably, heat dissipation teeth are arranged on the outer circumference of the inductor box.

[0014] Preferably, the sealing strip adopts a double-row sealing strip structure.

[0015] Preferably, the surface of the limiting partition in contact with the flat wire coil protrudes circumferentially from the flat wire coil.

[0016] In summary, the utility model provides a power inductor for high-power photovoltaic energy storage. The power inductor for high-power photovoltaic energy storage of the utility model has a simple structural design and a simple product production and assembly process, and is suitable for mass production. The nut connection method makes the product easy to assemble in terminal applications, and the modular inductor can be replaced and disassembled as a whole. Two inductor components share one inductor box, and materials such as films and soft wires are eliminated, making the product cost lower. The new limit partition structure design ensures that the inductor product is isolated and non-contacted from the inductor box. The inductor component and the inductor box can be directly heat-conducted through thermal conductive adhesive, which has a better heat dissipation effect and improves the work efficiency and reliability of the product.

[0017] This patent achieves the goal of improving the inductor power density, heat dissipation efficiency, reducing product volume, facilitating installation and disassembly, and reducing costs; and the overall structure adopts a solution of bending the lead, punching holes on the flat wire, and connecting with flange nuts. The partition is designed as a buckle boss structure to isolate the inductor and the inductor box, ensuring a certain insulation distance and playing an insulating role. It ensures that heat can be quickly transferred to the inductor box through the thermal conductive adhesive, reducing temperature rise and improving work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the overall structure of the high-power power inductor of the utility model;

[0019] Figure 2 It is a schematic diagram of the inductor box profiling design and the structure of the inductor box and the inductor assembly being separated in the utility model;

[0020] Figure 3 This is a schematic diagram of the internal structure of the inductor box of the utility model. Figure 1 ;

[0021] Figure 4 This is a schematic diagram of the internal structure of the inductor box of the utility model. Figure 2 ;

[0022] Figure 5 It is a schematic diagram of the installation structure of the limiting partition plate 1, limiting partition plate 2, fixing frame and supporting frame of the utility model;

[0023] Figure 6It is a schematic diagram of the structure of the limiting partition plate 1 and the limiting partition plate 2 of the utility model;

[0024] Figure 7 It is a schematic diagram of the joint end structure of the bending structure of the utility model;

[0025] Figure 8 It is a schematic diagram of the support frame structure of the utility model;

[0026] In the figure: inductor box 1, boss 2, sealing groove 3, sealing strip 4, center partition 5, inner cavity 51, inductor assembly 6, biaxial magnetic core 7, limit partition 1 11, limit partition 2 12, flat wire coil 13, connector end 14, support frame 15, flange nut 16, limit partition 17, limit platform 21, baffle 22, hook 23, fixing frame 24, wiring slot 1 25, positioning slot 26, slot 2 27, positioning rib 31, buckle part 32, hexagonal countersunk groove 33. DETAILED DESCRIPTION

[0027] The utility model is further described below in conjunction with the accompanying drawings.

[0028] like Figures 1 to 8 As shown:

[0029] The utility model is a power inductor for high-power photovoltaic energy storage, comprising an inductor box 1 which is positioned with an inverter casing by a boss 2 and then fixedly installed with the inverter casing, a sealing groove 3 is provided on the contact surface where the inductor box 1 is installed with the inverter casing, a sealing strip 4 is passed through the sealing groove 3 and sealed with the inverter casing, two inner cavities 51 are provided inside the inductor box 1, the two inner cavities 51 are separated by a central partition 5, the groove shape provided inside the inner cavity 51 is provided by profiling the shape of the inductor component 6, the inductor component 6 is fitted and placed inside the inner cavity 51, and a thermally conductive silica gel is poured into the gap between the inductor component 6 and the inner cavity 51, and the heat dissipation of the inductor component 6 is conducted by the transfer of the thermally conductive silica gel. The thermal characteristics are transferred to the inductor box 1. The inductor component 6 includes a dual-axis magnetic core 7. The two sides of the dual-axis magnetic core 7 are correspondingly sleeved with a limit partition 11 and a limit partition 2 12. The limit partition 11 and the limit partition 2 12 are used to limit the flat wire coil 13 wound on the magnetic core, and through the installation of the limit partition 11 and the limit partition 2 12, the magnetic core and the inductor box 1 are separated and do not contact each other. The connector end 14 of the flat wire coil 13 is installed at the upper limit position on the limit partition 2 12. The support frame 15 for locking the installation of the connector end 14 is clamped and installed on the limit partition 2 12. The support frame 15 is fixedly installed with the inverter terminal by setting a flange nut 16 inside, so as to be used for fixing the inverter terminal and the connector end 14.

[0030] In order to solve the technical problems of low heat dissipation efficiency and single installation space arrangement of the inductor box 1 in the prior art, the patent adopts the following structure: a contoured structure is adopted inside the inductor box 1, and two inner cavities 51 are opened in the shape of the inductor component 6. The inner cavity 51 is separated by a central partition 5. The inductor component 6 is placed and installed in the inner cavity 51, and the gap between the inductor component 6 and the inner cavity 51 is filled with thermally conductive silicone. The thermal conductivity of the thermally conductive silicone is 1.5W / m·K, and the thermal conductivity effect is nearly 7 times that of the prior art, thereby achieving a faster heat dissipation speed for the inductor component 6.

[0031] In order to realize the separation of the inductor component 6 and the inductor box 1, the inductor component 6 includes a biaxial magnetic core 7, each of which is wound with a flat wire coil 13, and the two sides of the flat wire coil 13 are correspondingly limited and installed by limiting partitions 11 and 12, and the protruding limiting partitions 11 and 12 are set by limiting partitions 11 and 12, so that the magnetic core and the inductor box 1 are separated and do not contact each other, and the gap is filled with thermal conductive silicone to achieve the technical characteristics of accelerated thermal conduction and separate installation of the magnetic core and the inductor box 1.

[0032] The connector end 14 of the flat wire coil 13 adopts a wire-free connection method, and the specific connection method is: a support frame 15 for locking and installing the connector end 14 is clamped and installed on the limiting partition plate 12, and a flange nut 16 is set inside the support frame 15 to fix the inverter terminal to the connector end 14; after the inductor assembly 6 and the inductor box 1 are installed, the inductor box 1 is first positioned with the inverter casing by setting a boss 2, and then fixedly installed with the inverter casing.

[0033] In at least one embodiment, a limiting partition 11 and a limiting partition 12 are used to separate the inductor assembly 6 from the inductor box 1. The specific structure is as follows: the limiting partition 11 and the limiting partition 12 both include a limiting partition 17 which is sleeved with the dual-axis magnetic core 7. The side surface of the limiting partition 17 close to the flat wire coil 13 is set as a limiting platform 21. The limiting platform 21 is set in contact with the end of the flat wire coil 13 to separate the flat wire coil 13 from the inductor box 1 without contact. The side surface of the limiting partition 17 away from the flat wire coil 13 is set as a baffle 22. The baffle 22 is evenly provided with hooks 23 in the circumferential direction. The hooks 23 are engaged with the end face of the dual-axis magnetic core 7. The end face of the hook 23 away from the baffle 22 protrudes from the end face of the dual-axis magnetic core 7 to separate the dual-axis magnetic core 7 from the inductor box 1 without contact through the protruding end face of the hook 23.

[0034] Specifically, the limiting partitions 17 on the limiting partition 11 and the limiting partition 2 12 are provided with sleeve through holes, and the sleeve through holes correspond to the sleeve installation of the biaxial magnetic core 7. The limiting partition 17 is provided with a limiting platform 21 on one side surface close to the flat wire coil 13, and the limiting platform 21 is arranged in contact with the end of the flat wire coil 13, so as to realize the limiting sleeve connection between the limiting platform 21 and the limiting platform 21, so as to realize the limiting installation of the flat wire coil 13 by the limiting partition 17. A baffle 22 is provided on one side surface away from the flat wire coil 13, and hooks 23 are evenly provided around the baffle 22. The hooks 23 are engaged with the end faces of the dual-axis magnetic core 7, and the ends of the hooks 23 protrude from the end faces engaged with the dual-axis magnetic core 7, so as to realize the protruding structural setting, separate the dual-axis magnetic core 7 from the inductor box 1 and prevent them from contacting each other, and separate the flat wire coil 13, the dual-axis magnetic core 7 and the inductor box 1, and fill the separated gaps with thermally conductive silicone to accelerate thermal conduction.

[0035] In at least one embodiment, the support frame 15 is installed by clamping with the second limiting partition 12 to realize the connection installation of the connector end 14 of the flat wire coil 13 without a wire. The structure adopted is: a fixing frame 24 is provided on the upper part of the limiting partition 17 on the second limiting partition 12, and the fixing frame 24 is provided with a wiring card slot 25 matching the connector end 14. The connector end 14 is installed along the wiring card slot 25, and an elliptical hole is formed at the top of the wiring card slot 25, and the end of the connector end 14 is tinned. The structure of the elliptical hole can reduce the difficulty of positioning accuracy and facilitate production operation.

[0036] A positioning groove 26 and a second groove 27 are correspondingly arranged on both sides of the wiring groove 1 25. A positioning rib 31 is provided at the end of the support frame 15 to match the positioning groove 26, and a buckle portion 32 is provided to match the second groove 27. The positioning rib 31 is positioned and installed with the positioning groove 26, and the buckle portion 32 is engaged with the second groove 27, so that the support frame 15 is fixedly installed on the fixing frame 24.

[0037] In at least one embodiment, a hexagonal groove 33 is provided in the middle of the support frame 15, and the groove is designed to be hexagonal to prevent the nut from rotating when tightening; a flange nut 16 is placed inside the hexagonal groove 33, and the joint end 14 is bent to contact the flange nut 16, and the joint end 14 is provided with a hexagonal groove 2 34 coaxial with the flange nut 16, and the inverter terminal passes through the hexagonal groove 2 34 and is threadedly installed with the hexagonal groove 33 to fix the inverter terminal and the joint end 14, thereby realizing quick connection of the joint end 14, eliminating the use of connecting wires, and reducing the use of space.

[0038] In at least one embodiment, the interface between the limiting partition 17 and the flat wire coil 13 is sealed with glue.

[0039] In at least one embodiment, a mounting hole 35 is provided in the circumference of the mating surface where the inductor box 1 and the inverter housing are mounted.

[0040] In at least one embodiment, heat dissipation teeth are provided on the outer circumference of the inductor box 1 .

[0041] At least in one embodiment, the sealing strip 4 adopts a double-row structure. The sealing strip 4 is designed in a double row, which has double sealing insurance and more reliable sealing, and can better achieve the purpose of waterproofing and dustproofing.

[0042] In at least one embodiment, the surface of the limiting partition 17 in contact with the flat wire coil 13 protrudes circumferentially from the flat wire coil 13 to separate the flat wire coil 13 from the inductor box 1, and the separated gap is filled with thermally conductive silicone to accelerate thermal conduction.

[0043] The product assembly steps are:

[0044] ①. The flat wire coil 13 is wound and installed on the biaxial magnetic core 7, and the flat wire coil 13 is limited and installed by the limiting partition 11 and the limiting partition 2 12 to realize the assembly and installation of the inductor component 6, and the flat wire coil 13 is bonded with glue.

[0045] ②, the hexagonal flange nut 16 is placed in the hexagonal groove 33 of the support frame 15, and the support frame 15 is clamped in the limiting partition 12;

[0046] ③. The inductor assembly 6 is placed in the inductor box 1, and two inductor assemblies 6 are placed in each inductor box.

[0047] ④. Pour thermal conductive silicone (thermal conductivity 1.5) into the inductor box 1, solidify it, and then test and inspect it.

[0048] The technical effects achieved by this patent are:

[0049] The inductor box 1 adopts a two-in-one design, and two inductor components 6 share one inductor box 1, which greatly reduces the cost of the inductor box, reduces the volume of the product, improves the power density of the inductor, and reduces the material cost.

[0050] 2. Compared with the traditional film insulation process, the buckle protrusion distance on the limit partition 17 is used to separate the insulation, eliminating the film material and process steps, and the heat transfer can be directly transferred to the heat dissipation teeth of the inductor box through the thermal conductive glue. The heat dissipation effect is better and the temperature rise of the power inductor is reduced.

[0051] 3. Compared with the traditional flat wire connected to the soft wire lead-out, this joint end 14 + flange nut 16 installation method can directly lock the terminal to the joint end 14 of the inductor component 6. Not only does it save the wire material and the wire connection process, reducing material costs, but it also saves space for soft wire wiring, improves the space inside the entire inverter, and can make the inverter smaller and more compact.

[0052] 4. The double-row sealing strip 4 is bonded in the sealing groove 3 of the inductor box 1, and the bonding is firm, does not shift, and does not fall off. The double-row sealing strip 4 is squeezed on the casing, and the sealing effect is safer and more reliable.

[0053] The utility model is a power inductor used for high-power photovoltaic energy storage. It has a simple structural design and a simple product production and assembly process, and is suitable for mass production. The nut connection method makes the product easy to assemble when it is used in a terminal application, and the modular inductor can be replaced and disassembled as a whole. Two inductor components 6 share one inductor box 1, and materials such as films and soft wires are eliminated, making the product cost lower. The new structure design of the limiting partition 17 ensures that the inductor product is isolated and non-contacted from the inductor box. The inductor component 6 and the inductor box 1 can be directly heat-conducted through thermal conductive glue, which has a better heat dissipation effect and improves the work efficiency and reliability of the product.

[0054] The embodiments of the present invention are only used to illustrate the present invention and do not constitute a limitation on the scope of the claims. Other substantially equivalent alternatives that can be thought of by those skilled in the art are all within the protection scope of the present invention.

Claims

1. A power inductor for high-power photovoltaic energy storage, characterized in that: The invention comprises the following steps: an inductor box (1) is positioned with an inverter casing by a boss (2) and then fixedly installed with the inverter casing; a sealing groove (3) is provided on the contact surface where the inductor box (1) and the inverter casing are installed; a sealing strip (4) is passed through the sealing groove (3) and the inductor box (1) is sealed with the inverter casing; two inner chambers (51) are provided inside the inductor box (1); the two inner chambers (51) are separated by a central partition (5); a groove is provided inside the inner chamber (51) and is provided in a shape that matches the shape of an inductor component (6); the inductor component (6) is placed in a close relationship with the inner chamber (51); a thermally conductive silica gel is poured into the gap between the inductor component (6) and the inner chamber (51); the heat dissipation of the inductor component (6) is transferred to the inductor box (1) through the heat transfer property of the thermally conductive silica gel; and the inductor component (6) is electrically conductively connected to the inductor box (1). The component (6) comprises a biaxial magnetic core (7), and two sides of the biaxial magnetic core (7) are correspondingly sleeved to form a limiting partition plate (11) and a limiting partition plate (12). The limiting partition plate (11) and the limiting partition plate (12) are used to limit the flat wire coil (13) wound on the magnetic core, and the magnetic core and the inductance box (1) are separated and do not contact each other through the installation of the limiting partition plate (11) and the limiting partition plate (12). The connector end (14) of the flat wire coil (13) is located on the limiting partition plate (12) and the supporting frame (15) for locking and installing the connector end (14) is clamped and installed on the limiting partition plate (12). The supporting frame (15) is fixedly installed with the inverter wiring terminal by arranging a flange nut (16) in the supporting frame (15), so as to be used for fixing the inverter wiring terminal and the connector end (14).

2. A power inductor for high-power photovoltaic energy storage according to claim 1, characterized in that: The first limiting baffle (11) and the second limiting baffle (12) both include a limiting baffle (17) sleeved with the biaxial magnetic core (7); a surface of the limiting baffle (17) on one side close to the flat wire coil (13) is provided as a limiting platform (21); the limiting platform (21) is provided in contact with the end of the flat wire coil (13) so as to separate the flat wire coil (13) from the inductance box (1) and prevent them from contacting each other; a surface of the limiting baffle (17) on one side away from the flat wire coil (13) is provided as a baffle (22); hooks (23) are evenly provided in the circumferential direction of the baffle (22); the hooks (23) are clamped with the end face of the biaxial magnetic core (7); the end face of the hook (23) away from the baffle (22) protrudes from the end face of the biaxial magnetic core (7) so as to separate the biaxial magnetic core (7) from the inductance box (1) and prevent them from contacting each other through the protruding end face of the hook (23).

3. A power inductor for high-power photovoltaic energy storage according to claim 2, characterized in that: A fixing frame (24) is arranged on the upper part of the limiting partition (17) on the limiting partition (12), and a wiring clamping groove (25) matching with the joint end (14) is provided on the fixing frame (24), and a positioning groove (26) and a second clamping groove (27) are arranged on both sides of the wiring clamping groove (25) correspondingly, and a positioning rib (31) is provided at the end of the supporting frame (15) to match the positioning groove (26), and a buckle portion (32) is provided to match the second clamping groove (27), and the supporting frame (15) is fixedly installed on the fixing frame (24) by positioning the positioning rib (31) and the positioning groove (26), and the buckle portion (32) is clamped with the second clamping groove (27).

4. A power inductor for high-power photovoltaic energy storage according to claim 3, characterized in that: The middle part of the support frame (15) is provided with a hexagonal recessed groove (33), a flange nut (16) is placed inside the hexagonal recessed groove (33), the joint end (14) is bent to contact the flange nut (16), and the joint end (14) is provided with a second hexagonal recessed groove (34) coaxial with the flange nut (16), the inverter wiring terminal passes through the second hexagonal recessed groove (34) and is threadedly installed with the hexagonal recessed groove (33), so as to fix the inverter wiring terminal and the joint end (14).

5. A power inductor for high-power photovoltaic energy storage according to claim 2, characterized in that: The butt joint surface between the limiting partition plate (17) and the flat wire coil (13) is sealed with glue.

6. A power inductor for high-power photovoltaic energy storage according to claim 1, characterized in that: A mounting hole (35) is provided in the circumferential direction of the butt joint surface where the inductor box (1) and the inverter housing are mounted.

7. A power inductor for high-power photovoltaic energy storage according to claim 1, characterized in that: Heat dissipation teeth are arranged on the outer circumference of the inductor box (1).

8. A power inductor for high-power photovoltaic energy storage according to claim 1, characterized in that: The sealing rubber strip (4) adopts a double-row sealing rubber strip (4) structure.

9. A power inductor for high-power photovoltaic energy storage according to claim 1, characterized in that: The surface of the limiting partition (17) in contact with the flat wire coil (13) is circumferentially protruding from the flat wire coil (13).

Images