Magnetic core device, motor controller and power assembly
Through the integrated injection molding process, the core and coil are covered, which solves the problems of large loss of core devices and high material costs, and achieves more efficient heat dissipation and production efficiency.
Patent Information
- Application Number
- CN202421671194.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-07-15
- Publication Date
- 2025-05-30
- Estimated Expiration
- 2034-07-15
AI Technical Summary
Existing core devices have large losses during use, requiring additional auxiliary heat dissipation, and the fixing and packaging processes use a lot of materials, resulting in high costs.
The integrated injection molding process is adopted to assemble the coil and the magnetic core, and then form an integrated injection molding piece to cover the core and the coil, and conduct thermal contact with it, replacing the traditional skeleton, shell and potting glue.
The integrated injection molding parts can achieve additional auxiliary heat dissipation of the magnetic core and coil, reducing material use, reducing assembly processes, improving production efficiency, and reducing thermal resistance.
Smart Images
Figure CN222927290U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of electromagnetic induction devices, in particular to a magnetic core device, a motor controller and a power assembly. Background Art
[0002] Currently, the automotive new energy industry uses a large number of magnetic core devices such as filter inductors and transformers. Due to the large loss of magnetic core devices, additional auxiliary heat dissipation is required.
[0003] In the related art, a skeleton is usually used to fix the magnetic core and the coil, and then a shell is installed. Finally, a potting compound is used to pot between the shell and the skeleton. A lot of materials are used, resulting in high costs. Utility Model Content
[0004] The main purpose of the utility model is to provide a magnetic core device, a motor controller and a power assembly, aiming at reducing material costs.
[0005] In order to achieve the above-mentioned purpose, the utility model provides a magnetic core device, comprising:
[0006] Magnetic core;
[0007] a coil, the coil being at least partially wound around the magnetic core;
[0008] An integral injection molded part, wherein the integral injection molded part covers the magnetic core and the coil and is in thermal contact with the magnetic core and the coil, and a pin of the coil extends out of the integral injection molded part.
[0009] In one embodiment, the integral injection molded part is a plastic part.
[0010] In one embodiment, the plastic part is a molded plastic part.
[0011] In one embodiment, the coil includes a winding and a pin segment, the winding is wound around the magnetic core, one end of the pin segment is connected to the winding, and one end of the pin segment away from the winding includes the pin;
[0012] The one-piece injection molded part includes a first covering part and a second covering part which are integrally connected. The first covering part covers the magnetic core and the winding, and the second covering part covers the pin segment. The pin extends out of the second covering part.
[0013] In one embodiment, the coil includes two pin segments that are spaced apart from each other, the two pin segments are an input end and an output end respectively, and each of the pin segments is covered with a second covering member.
[0014] In one embodiment, the second covering member includes a first pin covering section and a second pin covering section. The first pin covering section is located between the second pin covering section and the first covering member, and is integrally connected to the second pin covering section and the first covering member.
[0015] In the same coil, the two first pin covering sections respectively covering the two pin sections are connected by a connecting portion.
[0016] In one embodiment, the magnetic core at least includes a first leg and a second leg that are parallel to each other, and at least one of the coils is wound around the first leg and the second leg.
[0017] In one embodiment, the magnetic core further includes a first connecting section and a second connecting section that are parallel to each other. The two ends of the first connecting section are respectively connected to one end of the first leg and one end of the second leg, and the two ends of the second connecting section are respectively connected to the other end of the first leg and the other end of the second leg, so that the magnetic core forms a closed magnetic core.
[0018] To achieve the above object, the present application further provides a motor controller, including the above magnetic core device.
[0019] To achieve the above object, the present application further provides a powertrain, including a motor and the above motor controller, and the motor controller drives the motor to work.
[0020] Through the technical solution of the present utility model, after assembling the coil and the magnetic core, through an integral injection molding process, an integral injection molded part is formed outside the coil and the magnetic core, so as to cover the magnetic core and the coil through the integral injection molded part, and the integral injection molded part is in thermal contact with the magnetic core and the coil. Then, the integral injection molded part can be used to achieve additional auxiliary heat dissipation for the magnetic core and the coil, replacing the use of a skeleton, a housing, and potting glue. Thereby, the use of materials can be reduced, the material cost can be effectively reduced, at the same time, the assembly process can be reduced, the production efficiency can be effectively improved, and the thermal resistance is lower. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on the structures shown in these drawings.
[0022] Figure 1 It is a schematic structural diagram after assembling the magnetic core and the coil in an embodiment of the magnetic core device provided by the present utility model;
[0023] Figure 2 Schematic diagram of the structure of an integrally injection-molded part covering a magnetic core and a coil in an embodiment of the magnetic core device provided by the present utility model.
[0024] Explanation of the reference numerals in the attached drawings:
[0025] Label Name Label Name 100 Magnetic core device 22 Pin segment 10 Magnetic core 221 Pin 11 First leg 30 Integrally injection-molded part 12 Second leg 31 First covering part 13 First connection segment 32 Second covering part 14 Second connection segment 321 First pin covering segment 20 Coil 3211 Connection part 21 Winding 322 Second pin covering segment
[0026] The realization of the purpose, functional features and advantages of the present utility model will be further described with reference to the embodiments and the attached drawings. Specific embodiments
[0027] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described with reference to the attached drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present utility model.
[0028] It should be noted that if there are directional indications (such as up, down, left, right, front, back...) involved in the embodiments of the present utility model, the directional indications are only used to explain the relative positional relationship and movement conditions between components in a specific posture. If the specific posture changes, the directional indications will also change accordingly.
[0029] In addition, if there are descriptions such as "first", "second", etc. involved in the embodiments of the present utility model, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In addition, if "and / or" or "and / or" appears throughout the text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or a solution that satisfies both A and B at the same time. In addition, the technical solutions between the embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present utility model.
[0030] Currently, magnetic core devices such as filter inductors and transformers are widely used in the new energy industry of automobiles. Since the magnetic core devices have large losses, additional auxiliary heat dissipation is required.
[0031] In the related art, a skeleton is usually used to fix the magnetic core and the coil, then the outer shell is installed, and finally potting glue is used for potting between the outer shell and the skeleton. A lot of materials are used, resulting in high costs.
[0032] Based on the above problems, the present utility model proposes a magnetic core device, aiming to reduce the material cost. The magnetic core device can be applied to a motor controller, and the motor controller can be applied to a powertrain to drive the motor of the powertrain to work through the motor controller.
[0033] Please refer to Figure 1 and Figure 2 , in an embodiment of the present utility model, the magnetic core device 100 includes a magnetic core 10, a coil 20, and an integrally molded part 30; the coil 20 is at least partially wound around the magnetic core 10; the integrally molded part 30 covers the magnetic core 10 and the coil 20 and is in thermally conductive contact with the magnetic core 10 and the coil 20, and the lead 221 of the coil 20 extends out of the integrally molded part 30.
[0034] The technical solution of the present utility model, after assembling the coil 20 and the magnetic core 10, through an integrally molded process, forms an integrally molded part 30 outside the coil 20 and the magnetic core 10, so as to cover the magnetic core 10 and the coil 20 with the integrally molded part 30, and the integrally molded part 30 is in thermally conductive contact with the magnetic core 10 and the coil 20, then the integrally molded part 30 can be used to realize additional auxiliary heat dissipation for the magnetic core 10 and the coil 20, replacing the use of a bobbin, a housing, and potting glue, thereby being able to reduce the use of materials, effectively reduce the material cost, and at the same time be able to reduce the assembly process, effectively improve the production efficiency, and have a lower thermal resistance.
[0035] In addition, the traditional related technology also adopts the method of designing a cavity in the whole machine housing to pot the whole machine, which will make the process more complex and the wire body more bulky. However, in this solution, through the integrally molded process, an integrally molded part 30 is formed outside the coil 20 and the magnetic core 10, and then the integrally molded part 30 can be used to realize additional auxiliary heat dissipation for the magnetic core 10 and the coil 20. Compared with the method of potting the whole machine, the design of this solution adopts a simpler process and does not require a bulky wire body.
[0036] In this embodiment, the coil 20 can be first wound around the magnetic core 10 to realize the assembly of the coil 20 and the magnetic core 10 (at this time, there is no need to fix the coil 20 and the magnetic core 10), then the assembled semi-finished product is put into a mold, and the lead 221 of the coil 20 is positioned, and then the injection material is poured into the mold for the injection process. After the injection material is cooled and solidified, the integrally molded part 30 can be formed, so that the integrally molded part 30 covers the magnetic core 10 and the coil 20, and the lead 221 of the coil 20 extends out of the integrally molded part 30.
[0037] In practical applications, the injection material of the integrally molded part 30 can specifically be a metal material or a plastic material, as long as it can effectively cover the magnetic core 10 and the coil 20 to effectively assist the magnetic core 10 and the coil 20 in heat dissipation.
[0038] Optionally, refer to Figure 2 , in an embodiment of the present utility model, the integrally injection-molded part 30 can be a plastic part. With such a setting, by using plastic as the injection material, a plastic part covering the magnetic core 10 and the coil 20 is formed, so as to achieve additional auxiliary heat dissipation for the magnetic core 10 and the coil 20 through the plastic part. Compared with metal or other materials, plastic has a lower cost and a lower thermal resistance.
[0039] Furthermore, refer to Figure 2 , in an embodiment of the present utility model, the plastic part is a molded plastic part. With such a setting, by using the molded plastic as the injection material, a molded plastic part covering the magnetic core 10 and the coil 20 is formed, so as to achieve additional auxiliary heat dissipation for the magnetic core 10 and the coil 20 through the molded plastic part. Compared with other plastics (such as thermoplastics), the molded plastic has the following advantages: First, the required injection pressure is lower; Second, the required injection temperature is lower; Third, the thermal conductivity is better.
[0040] As some examples, the material of the molded plastic part can specifically be BMC (Bulk molding compounds, that is, bulk molding compound, also known as unsaturated polyester bulk molding compound), or it can also be EMC (EMC - Epoxy Molding Compound, that is, epoxy molding compound, epoxy encapsulant).
[0041] Please refer to Figure 1 and Figure 2 , in an embodiment of the present utility model, the coil 20 includes a winding 21 and a pin segment 22. The winding 21 is wound around the magnetic core 10. One end of the pin segment 22 is connected to the winding 21, and the end of the pin segment 22 far from the winding 21 includes a pin 221; the integrally injection-molded part 30 includes a first covering part 31 and a second covering part 32 that are integrally connected. The first covering part 31 covers the magnetic core 10 and the winding 21, and the second covering part 32 covers the pin segment 22, and the pin 221 extends outside the second covering part 32.
[0042] With such a setting, after the integrally injection-molded part 30 is formed by using the integrally injection molding process, the first covering part 31 of the integrally injection-molded part 30 can cover the magnetic core 10, so as to achieve additional auxiliary heat dissipation for the magnetic core 10 through the first covering part 31. At the same time, the second covering part 32 of the integrally injection-molded part 30 covers the coil 20, so as to achieve additional auxiliary heat dissipation for the coil 20 through the second covering part 32, thus effectively ensuring the additional auxiliary heat dissipation effect for the magnetic core 10 and the coil 20.
[0043] In practical applications, the two pin segments 22 of the same coil 20 can be covered by the same second covering member 32, or two independent second covering members 32 can be used to cover the two pin segments 22 respectively.
[0044] Please refer to Figure 1 and Figure 2 , in an embodiment of the present utility model, the coil 20 includes two pin segments 22 distributed at intervals. The two pin segments 22 are an input end and an output end respectively, and each pin segment 22 is covered with a second covering member 32.
[0045] With such a setting, by covering each pin segment 22 with an independent second covering member 32, the thermal resistance to the pin segment 22 can be reduced, so as to effectively improve the additional auxiliary heat dissipation effect on the pin segment 22.
[0046] Please refer to Figure 1 and Figure 2 , in an embodiment of the present utility model, the second covering member 32 includes a first pin covering segment 321 and a second pin covering segment 322. The first pin covering segment 321 is located between the second pin covering segment 322 and the first covering member 31, and is integrally connected to the second pin covering segment 322 and the first covering member 31; in the same coil 20, the two first pin covering segments 321 covering the two pin segments 22 are connected by a connecting portion 3211.
[0047] With such a setting, by connecting the two first pin covering segments 321 through the connecting portion 3211, the distance between the two pin segments 22 of the coil 20 can be ensured through the connecting portion 3211, so as to ensure the insulation distance between the two pin segments 22 of the coil 20, and avoid the distance between the two pin segments 22 of the coil 20 being too close to affect the use effect.
[0048] As an example, the side of the connecting portion 3211 close to the first covering member 31 can also be integrally connected to the first covering member 31, so as to improve the overall strength of the integral injection molded part 30.
[0049] Please refer to Figure 1 , in an embodiment of the present utility model, the magnetic core 10 at least includes a first leg 11 and a second leg 12 that are parallel to each other, and at least one coil 20 is wound around both the first leg 11 and the second leg 12.
[0050] With such a setting, by winding at least one coil 20 on both the mutually parallel first leg 11 and second leg 12, an interaction inductance can be generated between the coils 20.
[0051] In practical applications, the number of coils 20 wound on the first leg 11 and the second leg 12 can be the same or different.
[0052] See also Figure 1 In one embodiment of the utility model, the magnetic core 10 also includes a first connecting section 13 and a second connecting section 14 parallel to each other, the two ends of the first connecting section 13 are respectively connected to one end of the first leg 11 and one end of the second leg 12, and the two ends of the second connecting section 14 are respectively connected to the other end of the first leg 11 and the other end of the second leg 12, so that the magnetic core 10 forms a closed magnetic core 10.
[0053] In this way, by connecting the first leg 11, the first connecting section 13, the second leg 12 and the second connecting section 14 in sequence to form a closed magnetic core 10, the magnetic resistance of the magnetic core 10 can be effectively reduced to reduce the loss of the magnetic core device 100. The temperature generated by the magnetic core device 100 during operation is low when the loss is small, which is beneficial to improving the working efficiency of the magnetic core device 100 and extending its service life.
[0054] The utility model also proposes a motor controller, which includes a magnetic core device 100. The specific structure of the magnetic core device 100 refers to the above embodiment. Since the motor controller adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought by the technical solutions of the above embodiments, which will not be described one by one here.
[0055] The utility model also proposes a power assembly, which includes a motor and a motor controller. The specific structure of the motor controller refers to the above embodiment. Since the power assembly adopts all the technical solutions of all the above embodiments, it at least has all the beneficial effects brought by the technical solutions of the above embodiments, which will not be described one by one here. Among them, the motor controller drives the motor to work.
[0056] The above description is only an exemplary embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.
Claims
1. A magnetic core device, characterized in that: include: Magnetic core; a coil, the coil being at least partially wound around the magnetic core; An integral injection molded part, wherein the integral injection molded part covers the magnetic core and the coil and is in thermal contact with the magnetic core and the coil, and a pin of the coil extends out of the integral injection molded part.
2. The magnetic core device according to claim 1, characterized in that: The one-piece injection molded part is a plastic part.
3. The magnetic core device according to claim 2, characterized in that: The plastic part is a molded plastic part.
4. The magnetic core device according to any one of claims 1 to 3, characterized in that: The coil comprises a winding and a pin segment, the winding is wound around the magnetic core, one end of the pin segment is connected to the winding, and one end of the pin segment away from the winding comprises the pin; The one-piece injection molded part includes a first covering part and a second covering part which are integrally connected. The first covering part covers the magnetic core and the winding, and the second covering part covers the pin segment. The pin extends out of the second covering part.
5. The magnetic core device according to claim 4, characterized in that: The coil comprises two pin segments which are spaced apart from each other. The two pin segments are an input end and an output end respectively. Each of the pin segments is covered with a second covering member.
6. The magnetic core device according to claim 5, characterized in that: The second covering member includes a first pin covering section and a second pin covering section, the first pin covering section is located between the second pin covering section and the first covering member, and is integrally connected to the second pin covering section and the first covering member; In the same coil, two first pin covering sections respectively covered by two pin sections are connected via a connecting portion.
7. The magnetic core device according to any one of claims 1 to 3, characterized in that: The magnetic core at least comprises a first leg and a second leg parallel to each other, and both the first leg and the second leg are wound with at least one coil.
8. The magnetic core device according to claim 7, characterized in that: The magnetic core also includes a first connecting section and a second connecting section parallel to each other, wherein two ends of the first connecting section are respectively connected to one end of the first leg and one end of the second leg, and two ends of the second connecting section are respectively connected to the other end of the first leg and the other end of the second leg, so that the magnetic core forms a closed magnetic core.
9. A motor controller, characterized in that: Comprising the magnetic core device as claimed in any one of claims 1 to 8.
10. A powertrain, characterized in that: It comprises a motor and the motor controller as claimed in claim 9, wherein the motor controller drives the motor to operate.