Aluminum wire inductor

Abstract

The utility model provides an aluminum wire inductor which comprises a potting shell and a coil assembly installed in the potting shell. The inductance coil is an aluminum wire coil and is arranged by winding the iron core; and the coil joint is electrically connected with the inductance coil and comprises an aluminum joint section and a copper joint section which are integrated, the aluminum joint section is electrically connected with the end part of the aluminum coil, and the copper joint section is provided with a through hole. According to the utility model, the copper-aluminum transition bar is adopted, the outgoing line joint adopts a two-section type copper-aluminum splicing structure, the welding part of the outgoing line joint and the aluminum wire is made of aluminum, and the wiring through hole is processed in the copper part, so that the problems that the strength of the aluminum wire material is low after flattening and punching, and the installation strength cannot be ensured by welding a copper-clad aluminum bar by an aluminum wire inductor are solved.

Description

Technical Field

[0001] The utility model relates to the technical field of inductors, and particularly relates to an aluminum wire inductor. Background Art

[0002] With the progress of power electronics technology and photovoltaic power generation technology, high-frequency inductors in solar photovoltaic inverters, charging piles, UPSs, and energy storage devices face greater challenges. Solar inverters, charging piles, UPSs, and energy storage devices have high working frequencies and require light weight and high efficiency.

[0003] An inductor is a commonly used circuit component in devices such as inverters, charging piles, UPSs, and energy storage devices. The inductor structure includes an iron core, a coil, etc. In traditional technologies, the coil uses a copper wire coil, which has a high cost and a heavy overall weight of the product.

[0004] Due to the need to reduce costs and weight, inductor products gradually change the copper wire coil to an aluminum wire coil. The wire outlet end of the coil needs to be processed with a punching hole to facilitate wiring and connecting to other components. However, the product structure is bending, flattening, and punching. The aluminum wire is relatively soft, and it becomes thinner and more fragile after flattening, especially the bending part is easy to break. Most of such aluminum wire inductors adopt welding a copper-clad aluminum row to avoid this problem. For example, patent CN204926954U discloses an inductor with a copper-aluminum welded joint arranged at the wire outlet position.

[0005] However, in the prior art, the copper-clad aluminum row is only plated with a layer of copper on the upper surface of the aluminum row, and the overall hardness of the joint is low, and it is easy to flatten the wire when screwing the screw for installation, and the strength is unreliable. Summary of the Utility Model

[0006] The purpose of the utility model is to solve one of the above technical problems, and provide an aluminum wire inductor, which improves the structure of the inductor joint, while ensuring a stable wire outlet connection structure, improves the hardness of the wire outlet joint, and facilitates the installation and use of the aluminum wire inductor.

[0007] To achieve the above purpose, the technical solution adopted by the utility model is:

[0008] An aluminum wire inductor includes a potting housing and a coil assembly installed in the potting housing. The coil assembly includes:

[0009] An iron core;

[0010] An inductor coil: an aluminum wire coil wound around the iron core;

[0011] A coil joint: electrically connected to the inductor coil. The coil joint includes an integral aluminum joint section and a copper joint section. The aluminum joint section is electrically connected to the end of the aluminum wire coil, and the copper joint section is provided with a through hole.

[0012] In some embodiments of the present utility model, the coil wire of the aluminum wire coil is a flat wire, and the width of the end of the aluminum joint section connected to the aluminum wire coil is equal to the width of the aluminum wire coil.

[0013] In some embodiments of the present utility model, the aluminum joint section is connected to the inductance coil by welding.

[0014] In some embodiments of the present utility model, the aluminum joint section includes a first joint section and a second joint section. The first joint section is connected to the aluminum wire coil, and the copper joint section and the second joint section are of an integral structure.

[0015] In some embodiments of the present utility model, the first joint section and the second joint section are bent at 90°.

[0016] In some embodiments of the present utility model, the width of the first joint section is equal to the width of the aluminum wire coil.

[0017] In some embodiments of the present utility model, the width of the second joint section is greater than the width of the first joint section.

[0018] In some embodiments of the present utility model, the width of the second joint section is equal to the width of the copper joint section.

[0019] In some embodiments of the present utility model, the aluminum joint section and the copper joint section are connected by welding.

[0020] The beneficial effects of the aluminum wire inductor provided by the present utility model are as follows:

[0021] The present utility model adopts a copper-aluminum transition row, and the outgoing line joint adopts a two-section copper-aluminum splicing structure. The part welded to the aluminum wire is aluminum, and a wiring through-hole is processed in the copper part, which solves the problem that the strength of the aluminum wire material is low and the strength is insufficient after being flattened and punched, and at the same time, the welding of the aluminum wire inductor to the copper-clad aluminum row is not enough to ensure the installation strength. It can also improve the dimensional accuracy of the product installation holes, improve production efficiency and reduce labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model, the following will briefly introduce the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings in the following description 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 these drawings.

[0023] Figure 1 It is a schematic diagram of the coil joint structure.

[0024] Figure 2 It is a schematic diagram of the inductance coil structure.

[0025] Figure 3 It is a schematic diagram of the assembly structure of an inductance coil and an iron core.

[0026] Figure 4 It is a schematic diagram of the assembly structure of an inductance coil and a potting housing.

[0027] Among them:

[0028] 1 - Potting housing;

[0029] 2 - Iron core;

[0030] 3 - Inductance coil, 301 - Aluminum joint section, 3011 - First joint section, 3012 - Second joint section, 302 - Copper joint section, 303 - Through hole. Specific implementation manner

[0031] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present utility model clearer and more understandable, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present utility model and are not used to limit the present utility model.

[0032] In the description of this application, it should be noted that the fixed connection described in this application can be a detachable fixed connection or an integral fixed connection; the orientation or position relationship indicated is based on the position relationship shown in the drawings, and is only for the convenience of describing this application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to this application.

[0033] The terms "first" and "second" are only used for descriptive purposes and do not imply relative importance.

[0034] The present utility model provides an aluminum wire inductor, and the structure refers to Figures 2 to 3 , including a potting housing 1 and a coil assembly installed in the potting housing 1.

[0035] The coil assembly includes an iron core 2 and an inductance coil 3 wound around the outside of the iron core 2.

[0036] The inductance coil 3 is an aluminum wire coil and is arranged around the outer circumference of the iron core 2; in this embodiment, the inductance coil 3 is a flat wire with a certain width.

[0037] The coil joint 3 is electrically connected to the inductance coil 3, refer to Figure 1, the coil joint 3 adopts a copper-aluminum transition row, including an integrated aluminum joint section 301 and a copper joint section 302. The aluminum joint section 301 is electrically connected to the end of the aluminum wire coil and serves as a terminal. The copper joint section 302 is provided with a through hole 303. The aluminum joint section 301 and the copper joint section 302 can be connected by welding. The aluminum joint section 301 and the inductance coil can also be connected by welding.

[0038] In some embodiments of the present invention, the coil wire of the aluminum wire coil is a flat wire, and the width of the end of the aluminum joint section 301 connected to the aluminum wire coil is equal to the width of the aluminum wire coil. Adopting an equal-width structure facilitates welding and can ensure the stability of the electrical connection performance.

[0039] In some embodiments of the present invention, the aluminum joint section 301 includes a first joint section 3011 and a second joint section 3012, and the first joint section 3011 and the second joint section 3012 are bent between them. The bending angle between the two joint sections can be designed according to the requirements in the use working conditions. In the preferred implementation structure, the first joint section 3011 and the second joint section 3012 are bent at 90°, and such a design can save the wire outlet space.

[0040] The first joint section 3011 is connected to the aluminum wire coil, and the copper joint section 302 and the second joint section 3012 are of an integral structure. In this structure, since the first joint section 3011 is connected to the aluminum wire coil, therefore, the width of the first joint section 3011 is equal to the width of the aluminum wire coil.

[0041] Since the second joint section 3012 is connected to the copper joint section 302, and the copper joint section 302 is wider, in order to ensure the reliability of the connection between the aluminum joint section 301 and the copper joint section 302, the widths of the joint ends of the two are equal. Therefore, in some embodiments of the present invention, the width of the second joint section 3012 is greater than the width of the first joint section 3011, and the width of the second joint section 3012 is equal to the width of the copper joint section 302, which facilitates the welding connection between the two.

[0042] After the coil is wound, a laser welding machine is used to weld the coil pins to the copper-aluminum transition row, and then the aluminum wire coil 3, the magnetic core 2, and the baffle are assembled together to form an inductor body, and then the inductor body is placed in the potting shell 1 and filled with a heat-conducting potting adhesive to cover the inductor body.

[0043] Using a copper-aluminum transition row can avoid the risk of low strength and easy breakage after pure aluminum wire is flattened, and at the same time, it also makes the dimensional accuracy of the wiring through holes of the product higher and easier to control, solving problems such as easy skew of the wire outlet pins and non-conformance of the installation hole dimensions when directly bending, flattening, and punching the aluminum joint coil. Directly using a copper-aluminum transition row with fixed dimensions only requires controlling the welding of the copper-aluminum transition row and the aluminum coil, greatly improving the production efficiency and the product qualification rate, and reducing the labor cost.

[0044] The above are only the preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. An aluminum wire inductor, characterized in that, Comprising a potting housing and a coil assembly installed within the potting housing, the coil assembly includes: An iron core; An inductance coil: an aluminum wire coil wound around the iron core; A coil connector: electrically connected to the inductance coil, the coil connector includes an integral aluminum connector section and a copper connector section, the aluminum connector section is electrically connected to the end of the aluminum wire coil, and the copper connector section is provided with a through hole.

2. The aluminum wire inductor according to claim 1, wherein The coil wire of the aluminum wire coil is a flat wire, and the width of the end of the aluminum connector section connected to the aluminum wire coil is equal to the width of the aluminum wire coil.

3. The aluminum wire inductor according to claim 1 or 2, characterized in that, The aluminum connector section is welded to the inductance coil.

4. The aluminum wire inductor according to claim 1 or 2, characterized in that, The aluminum connector section includes a first connector section and a second connector section, the first connector section is connected to the aluminum wire coil, and the copper connector section and the second connector section are of an integral structure.

5. The aluminum wire inductor according to claim 4, wherein The first connector section is bent at 90° with respect to the second connector section.

6. The aluminum wire inductor according to claim 4, wherein The width of the first connector section is equal to the width of the aluminum wire coil.

7. The aluminum wire inductor according to claim 6, wherein The width of the second connector section is greater than the width of the first connector section.

8. The aluminum wire inductor according to claim 7, wherein The width of the second connector section is equal to the width of the copper connector section.

9. The aluminum wire inductor according to claim 1, characterized in that, The aluminum connector section and the copper connector section are welded together.

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