Coil monomer, coil winding and magnetic element
Through the stacking arrangement of sheet coils and the coil monomer structure connected in parallel, the problems of loss and temperature increase in magnetic components are solved, more efficient heat dissipation and lower losses are achieved, and the reliability of magnetic components is improved.
Patent Information
- Application Number
- CN202422087366.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-27
- Publication Date
- 2025-07-22
- Estimated Expiration
- 2034-08-27
AI Technical Summary
In existing magnetic components, the coil winding loss and temperature rise are high, resulting in the component being prone to failure and difficulty in dissipating heat in a limited space.
A plurality of sheet coils are laminated to form a heat dissipation channel and a coil monomer structure connected in parallel to reduce resistance and skin effects, enhance heat dissipation and reduce losses.
Reduces the temperature rise and loss of coil windings and magnetic components, improves reliability and extends service life.
Smart Images
Figure CN223140525U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of coils, and particularly to a coil unit, a coil winding, and a magnetic component. Background Art
[0002] Magnetic components are essential power electronic devices for energy storage, energy conversion, and electrical isolation. Magnetic components mainly include inductors and transformers, and usually include a coil winding and a magnetic core.
[0003] Existing power circuits not only require magnetic components to be smaller in size, but also require magnetic components to have characteristics such as high efficiency, low loss, and low temperature rise. As an important part of magnetic components, the coil winding has relatively high losses and temperature rise during operation. Especially at high frequencies, due to the skin effect on the surface of the conductor, this leads to an increase in the losses of the coil winding, and thus the temperature of the magnetic component is higher. On the other hand, within a limited space, the heat dissipation of the magnetic component is also limited. Therefore, the magnetic component is prone to aging, thermal fatigue, etc. at high temperatures, and even easily leads to the failure of the magnetic component. Summary of the Utility Model
[0004] This application provides a coil unit, a coil winding, and a magnetic component to solve the technical problem that the coil winding in the magnetic component has relatively high losses and temperature rise, which easily leads to the failure of the magnetic component.
[0005] According to a first aspect, in one embodiment, a coil unit is provided, including a plurality of sheet-like coils. The sheet-like coils are formed by winding a strip-shaped wire. The sheet-like coil includes a coil body, a first connection section, and a second connection section. The first connection section and the second connection section are respectively connected to two ends of the coil body in the winding direction. The plurality of sheet-like coils are stacked in the thickness direction of the strip-shaped wire, and adjacent two sheet-like coils are spaced apart to form a heat dissipation channel. The first connection sections of all the sheet-like coils are connected, and the second connection sections of all the sheet-like coils are connected.
[0006] In an optional embodiment, the direction of the winding axis of the coil body is the same as the thickness direction of the strip-shaped wire; or, the direction of the winding axis of the coil body is the same as the width direction of the strip-shaped wire.
[0007] In an optional embodiment, the coil body has an open-loop structure, and the strip-shaped wire is wound once to form the coil body.
[0008] In an alternative embodiment, the direction of the winding axis of the coil body is the same as the thickness direction of the strip-shaped wire, and the dimension of the coil body in the direction of the winding axis is equal to the thickness dimension of the strip-shaped wire; or, the direction of the winding axis of the coil body is the same as the width direction of the strip-shaped wire, and the dimension of the coil body in the direction of the winding axis is equal to the width dimension of the strip-shaped wire.
[0009] In an alternative embodiment, the first connecting section and the second connecting section are arranged at intervals in the winding direction of the coil body;
[0010] The direction of the winding axis of the coil body is the same as the thickness direction of the strip-shaped wire, and the dimension of the sheet-shaped coil in the direction of the winding axis is equal to the thickness dimension of the strip-shaped wire; or, the direction of the winding axis of the coil body is the same as the width direction of the strip-shaped wire, and the dimension of the sheet-shaped coil in the direction of the winding axis is equal to the width dimension of the strip-shaped wire.
[0011] In an alternative embodiment, the orientation of the first connecting section is opposite to the orientation of the second connecting section; or, the orientation of the first connecting section is the same as the orientation of the second connecting section, and the first connecting section and the second connecting section are arranged at intervals.
[0012] In an alternative embodiment, the first connecting section has a first connecting end and a first suspension end at its two ends. The first connecting end is connected to the coil body, and two adjacent first suspension ends in the thickness direction of the strip-shaped wire are connected; and / or,
[0013] The second connecting section has a second connecting end and a second suspension end at its two ends. The second connecting end is connected to the coil body, and two adjacent second suspension ends in the thickness direction of the strip-shaped wire are connected.
[0014] In an alternative embodiment, in the thickness direction of the strip-shaped wire, two adjacent first connecting sections are connected by a solder layer, and / or, two adjacent second connecting sections are connected by a solder layer.
[0015] In an alternative embodiment, an anti-oxidation layer is attached to the surface of the sheet-shaped coil.
[0016] In an alternative embodiment, the coil unit includes a support structure. The support structure is located between two adjacent coil bodies in the thickness direction of the strip-shaped wire, so that a preset gap for forming the heat dissipation channel is provided between two adjacent coil bodies.
[0017] According to a second aspect, in one embodiment, a coil winding is provided, which includes a plurality of the coil units described in any one of the above, the winding axes of all the coil bodies are coaxial, two adjacent coil bodies are arranged in the winding direction of the coil body and / or in the direction where the winding axis is located, and all the coil units are connected in series and / or in parallel.
[0018] According to a third aspect, in one embodiment, a magnetic component is provided, which includes a magnetic core member and also includes the coil unit described in any one of the above or the above coil winding.
[0019] Based on the coil unit, coil winding and magnetic component according to the above embodiments, the coil unit includes a plurality of sheet-like coils formed by winding a strip-shaped wire. The sheet-like coil includes a coil body, a first connection section and a second connection section. The first connection section and the second connection section are respectively connected to both ends in the winding direction of the coil body. The plurality of sheet-like coils are stacked in the thickness direction of the strip-shaped wire. Two adjacent sheet-like coils are arranged at intervals to form a heat dissipation channel, which can increase the heat transfer coefficient of the coil unit, the entire coil winding and the magnetic component through the heat dissipation channel, thereby reducing the temperature rise. The first connection sections of all the sheet-like coils are connected, and the second connection sections of all the sheet-like coils are connected. In this way, the coil unit forms a multi-layer sheet-like structure connected in parallel. While ensuring good contact at each end of the multi-layer sheet-like coil, it can reduce the resistance of the entire coil unit, thereby reducing the DC loss of the coil unit, the entire coil winding and the magnetic component. And the structure of the multi-layer sheet-like coils stacked can reduce the skin effect in the high-frequency state, thereby reducing the AC loss of the coil unit, the entire coil winding and the magnetic component, which helps to improve the reliability of the coil winding and the magnetic component. Description of the Drawings
[0020] Figure 1 It is a schematic structural diagram of a coil unit in one embodiment;
[0021] Figure 2 It is a schematic structural diagram of a coil unit in another embodiment;
[0022] Figure 3 It is a schematic structural diagram of a coil unit in another embodiment;
[0023] Figure 4 It is a schematic structural diagram of a coil unit in yet another embodiment;
[0024] Figure 5 It is a partially exploded structural schematic diagram of a prior art cross-inductor voltage regulator;
[0025] Figure 6 It is a schematic structural diagram of a cross-inductor voltage regulator in one embodiment;
[0026] Figure 7 For Figure 5Temperature rise distribution diagram of the outer coil of the intermediate cross-inductor voltage regulator when passing 50A direct current;
[0027] Figure 8 For Figure 6 Temperature rise distribution diagram of the outer coil of the intermediate cross-inductor voltage regulator when passing 50A direct current.
[0028] In the figure: 1. Chip coil; 10. Heat dissipation channel; 11. Coil body; 12. First connection section; 121. First connection end; 122. First suspension end; 13. Second connection section; 131. Second connection end; 132. Second suspension end; 21. Outer shell magnetic core; 22. Middle column magnetic core; 23. Outer coil; 24. Inner coil. Detailed implementation mode
[0029] The following further describes the present application in detail through specific implementation modes in combination with the accompanying drawings. Similar elements in different implementation modes adopt related similar element numbers. In the following implementation modes, many detailed descriptions are for better understanding of the present application. However, those skilled in the art can easily recognize that some of the features can be omitted in different situations, or can be replaced by other elements, materials, and methods. In some cases, some operations related to the present application are not shown or described in the specification, which is to avoid the core part of the present application being submerged by excessive descriptions. For those skilled in the art, it is not necessary to describe these related operations in detail, and they can fully understand the related operations according to the description in the specification and the general technical knowledge in the field.
[0030] In addition, the features, operations, or characteristics described in the specification can be combined in any appropriate manner to form various implementation modes, and the operation steps involved in each embodiment can also be adjusted or reordered in an obvious manner by those skilled in the art. Therefore, the specification and the drawings are only for clearly describing a certain embodiment, and do not mean to be the necessary composition and / or order.
[0031] The serial numbers assigned to the components herein, such as "first", "second", etc., are only used to distinguish the described objects and do not have any sequential or technical meaning. And the "connection" and "coupling" mentioned in the present application, unless otherwise specified, both include direct and indirect connection (coupling).
[0032] The embodiment of the present application discloses a coil unit, which can be applied in a coil winding or can also be applied in a magnetic component, such as an inductor or a transformer, to reduce the loss and temperature rise of the coil winding and the magnetic component, thereby reducing the probability of coil winding failure and improving the reliability of the coil winding and the magnetic component.
[0033] For the coil unit disclosed in the embodiment of the present application, please refer toFigures 1 to 4 , including a plurality of sheet coils 1, the sheet coils 1 are formed by winding a strip-shaped wire, the strip-shaped wire is wound along its length direction, and the width dimension of the strip-shaped wire is much larger than its thickness dimension, so that the wound strip-shaped wire is a thin sheet structure.
[0034] The sheet coil 1 includes a coil body 11, a first connection section 12 and a second connection section 13. In some embodiments, please refer to Figure 1 , the direction of the winding axis of the coil body 11 is the same as the width direction of the strip-shaped wire, that is, the strip-shaped wire is bent in its length direction and thickness direction. In other embodiments, please refer to Figures 2 to 4 , the direction of the winding axis of the coil body 11 is the same as the thickness direction of the strip-shaped wire, that is, the strip-shaped wire is bent in its length direction and width direction.
[0035] In some embodiments, please continue to refer to Figures 2 to 4 , the strip coil is wound to form the coil body 11, and the structure enclosed by the coil body 11 can be a circular, oval or rectangular structure; of course, in some other embodiments, the structure enclosed by the coil body 11 can also be a trapezoidal, triangular or other special-shaped structure, and the shape of the structure enclosed by the coil body 11 matches the cross-sectional shape of the magnetic core body surrounded by the coil body 11, and the shape of the structure enclosed by the coil body 11 depends on the cross-sectional shape of the magnetic core body surrounded by the coil body 11.
[0036] In some embodiments, please refer to Figures 1 to 4 , the coil body 11 has an open-loop structure, and the strip-shaped wire is wound around once to form the coil body 11, which does not mean that the two ends of the coil body 11 in its winding direction are in contact. In the embodiment where the shape of the enclosed structure of the coil body 11 is circular, the central angle corresponding to the coil body 11 in its winding direction is about 270°, that is, the strip-shaped wire corresponding to the coil body 11 is wound three-quarters of a circle. Since the coil body 11 formed by winding the strip-shaped wire three-quarters of a circle can meet the magnetic field change requirements after the coil body 11 is energized, winding the strip-shaped wire three-quarters of a circle can be considered as winding the strip-shaped wire around once; in the embodiments where the shape of the coil body 11 is trapezoidal, rectangular or other special-shaped structures, the central angle corresponding to the coil body 11 can be understood as the included angle between the two ends of the coil body 11 and the connection line between the geometric center of the enclosed shape of the coil body 11, and this included angle faces the direction of the coil body 11. As long as the included angle range is 270° to 360°, it can be considered that the strip-shaped wire corresponding to the coil body 11 is wound around once.
[0037] In some other embodiments, the strip-shaped wire corresponding to the coil body 11 can also be wound half a turn or one-third of a turn. When the coil body 11 is applied to a coil winding or a magnetic component, an external wire or coil needs to be additionally provided to ensure that the central angle of the structure formed by enclosing the coil body 11 with the external wire or the coil is greater than 270°, so that the magnetic field change requirements are met when the coil winding is energized.
[0038] Of course, in some other embodiments, the number of turns of the strip-shaped wire corresponding to the coil body 11 can also be greater than one turn. For example, the strip-shaped wire is wound one and a half turns, or two turns or more than three turns to form the coil body 11.
[0039] In some embodiments, please refer to Figure 1 , the strip-shaped wire is wound one turn to form the coil body 11, and the direction of the winding axis of the coil body 11 is the same as the width direction of the strip-shaped wire. The dimensions of the coil body 11 in the direction of the winding axis are equal everywhere, and the dimensions of the coil body 11 in the direction of the winding axis are equal to the width dimension of the strip-shaped wire. That is, the strip-shaped wire is wound in a plane perpendicular to its width direction to form the coil body 11. The coil body 11 is wound in a plane, and the positions of the two ends of the coil body 11 in the direction of the winding axis corresponding to each other in its winding direction, so as to facilitate the processing and manufacturing of the coil body 11.
[0040] In some other embodiments, please refer to Figures 2 to 4 , the strip-shaped wire is wound one turn to form the coil body 11, and the direction of the winding axis of the coil body 11 is the same as the thickness direction of the strip-shaped wire. The dimensions of the coil body 11 in the direction of the winding axis are equal everywhere, and the dimensions of the coil body 11 in the direction of the winding axis are equal to the thickness dimension of the strip-shaped wire. That is, the strip-shaped wire is wound in a plane perpendicular to its thickness direction to form the coil body 11. The coil body 11 is wound in a plane, and the positions of the two ends of the coil body 11 in the direction of the winding axis corresponding to each other in its winding direction, so as to facilitate the processing and manufacturing of the coil body 11.
[0041] Of course, in other embodiments, regardless of whether the strip-shaped wire forming the coil body 11 is wound one turn, less than one turn or multiple turns, and regardless of whether the direction of the winding axis of the coil body 11 is the same as the width direction of the strip-shaped wire or the thickness direction of the strip-shaped wire, the coil body 11 can be wound in a plane, that is, the positions of the two ends of the coil body 11 in the direction of the winding axis corresponding to each other in its winding direction; or the coil body 11 can also be wound in a spiral arrangement, and the positions of the two ends of the coil body 11 in the direction of the winding axis are staggered.
[0042] In the sheet coil 1, the first connection section 12 and the second connection section 13 are respectively connected to both ends of the coil body 11 in the winding direction. Please refer to Figures 1 to 4 , the first connection section 12 and the second connection section 13 can be arranged at intervals in the winding direction of the coil body 11, so as to avoid short - circuiting at both ends of the coil body 11 and facilitate the connection of both ends of the coil body 11 to external wires or coils respectively.
[0043] In some embodiments, please refer to Figure 1 , the direction of the winding axis of the coil body 11 is the same as the width direction of the strip - shaped wire. The dimension of the sheet coil 1 in the direction of the winding axis is equal to the width dimension of the strip - shaped wire. That is, in the direction of the winding axis, the dimension of the sheet coil 1 composed of the coil body 11, the first connection section 12 and the second connection section 13 is equal to the width dimension of the strip - shaped wire. The entire sheet coil 1 is wound and formed in a plane perpendicular to the width direction of the strip - shaped wire, so as to facilitate the winding of the entire strip - shaped wire.
[0044] In other embodiments, please refer to Figures 2 to 4 , the direction of the winding axis of the coil body 11 is the same as the thickness direction of the strip - shaped wire. The dimension of the sheet coil 1 in the direction of the winding axis is equal to the thickness dimension of the strip - shaped wire. That is, in the direction of the winding axis, the dimension of the sheet coil 1 composed of the coil body 11, the first connection section 12 and the second connection section 13 is equal to the thickness dimension of the strip - shaped wire. The entire sheet coil 1 is wound and formed in a plane perpendicular to the thickness direction of the strip - shaped wire, so as to also facilitate the winding of the entire sheet coil 1. Of course, in some other embodiments, it is also possible to only limit the coil body 11 to be wound in a plane perpendicular to the width or thickness direction of the strip - shaped wire, and the included angle between the extending direction of the first connection section 12 and / or the second connection section 13 and the direction of the winding axis is less than 90°, so as to facilitate the connection of two adjacent sheet coils 1 in the direction of the winding axis.
[0045] Please refer to Figures 1 to 4 , the first connection section 12 has a first connection end 121 and a first suspension end 122 at its two ends. The first connection end 121 is connected to the coil body 11. The second connection section 13 has a second connection end 131 and a second suspension end 132 at its two ends. The second connection end 131 is connected to the coil body 11. The orientation of the first connection section 12 is the direction from the first connection end 121 to the first suspension end 122, and the orientation of the second connection section 13 is the direction from the second connection end 131 to the second suspension end 132.
[0046] In some embodiments, please continue to refer to Figures 1 to 3, the sheet coil 1 is wound in a plane perpendicular to the winding axis direction. The coil body 11 is wound one turn or less than one turn. The first connection section 12 and the second connection section 13 are arranged at intervals in the winding direction of the coil body 11. The first connection section 12 and the second connection section 13 face the same direction, and the direction of the first connection section 12 faces away from the structure enclosed by the coil body 11. Or the directions of the first connection section 12 and the second connection end 131 can also be different. For example, the direction of the first connection section 12 can be opposite to the direction of the second connection section 13, so as to facilitate the connection between two adjacent coil units in the winding axis direction or the connection between the coil unit and other wires or coils.
[0047] In some other embodiments, in the structure where only the coil body 11 is wound in a plane perpendicular to the winding axis direction, the first connection section 12 and the second connection section 13 can also face one side or both sides of the winding axis direction, or make the angle between the direction of the first connection section 12 and / or the second connection section 13 and the winding axis direction less than 90°. In this way, it is also convenient for the electrical connection between the coil unit and the coil units, wires or coils arranged at intervals in the winding axis direction.
[0048] Or in some other embodiments, the coil body 11 is arranged to be wound in a spiral shape. The coil body 11 can be wound one turn, less than one turn or can also be wound multiple turns. The first connection section 12 and the second connection section 13 can be arranged at intervals in the winding axis direction. The first connection section 12 and the second connection section 13 face the same direction. In this way, it is also convenient for the electrical connection between the coil unit and the wires or coils arranged at intervals in the winding axis direction.
[0049] Of course, in other embodiments, regardless of whether the coil body 11 is wound in a plane perpendicular to the winding axis direction, and regardless of whether the coil body 11 is wound one turn, less than one turn or multiple turns, as long as the first connection section 12 and the second connection section 13 are arranged at intervals and the first connection section 12 and the second connection section 13 will not be short-circuited.
[0050] In the coil unit of the embodiment of the present application, there are multiple sheet coils 1. The multiple sheet coils 1 are stacked in the thickness direction of the strip-shaped wire. In this way, the skin effect of the entire coil unit can be reduced through the structure of the stacked multiple sheet coils 1, thereby reducing the AC loss of the coil unit. In some embodiments, please refer to Figure 1, the direction of the winding axis of the coil body 11 is the same as the width direction of the strip wire. A plurality of sheet-shaped coils 1 are arranged in a direction gradually away from the winding axis of the coil body 11. In this case, it is required that the winding radius of the coil body 11 farther from the winding axis is slightly larger than that of the coil body 11 closer to the winding axis. Moreover, in order to ensure that the end faces of the first suspension ends 122 of the plurality of sheet-shaped coils 1 are flush and the end faces of the second suspension ends 132 are flush, to facilitate the connection between the coil unit and adjacent coil units, wires or coils, it is also required that the length of the sheet-shaped coil 1 farther from the winding axis, that is, the length of the strip wire, is slightly larger than that of the sheet-shaped coil 1 closer to the winding axis.
[0051] In some other embodiments, please refer to Figures 2 to 4 , the direction of the winding axis of the coil body 11 is the same as the thickness direction of the strip wire. The dimensions between each layer-stacked sheet-shaped coil 1 and the winding axis direction of the coil body 11 are all equal. In this way, the winding radius of each coil body 11 and the length dimension of each coil body 11 are all equal. In this way, it is convenient for the processing and manufacturing of each sheet-shaped coil 1 in the coil unit, helps to reduce the processing accuracy requirements for each sheet-shaped coil 1, and also helps to reduce the resistance of the coil unit, thereby reducing the loss of the coil unit.
[0052] To facilitate the connection between the coil unit and the remaining wires or coils, the first connection segments 12 of each sheet-shaped coil 1 in the coil unit are connected, and the second connection segments 13 of each sheet-shaped coil 1 are connected. Specifically, please refer to Figures 1 to 4 , the two second suspension ends 132 adjacent in the thickness direction of the strip wire are connected, and the adjacent two first suspension ends 122 are connected. On the premise of ensuring that the plurality of first suspension ends 122 and the plurality of second suspension ends 132 are respectively connected, the resistance of the entire coil unit can be reduced by the parallel-connected sheet-shaped coils 1, thereby reducing the DC loss of the coil unit. Of course, in other embodiments, the specific connection positions of the plurality of first connection segments 12 and the plurality of second connection segments 13 may not be limited. The plurality of first connection segments 12 can be connected at any position between the first connection end 121 and the first suspension end 122, and the plurality of second connection segments 13 can be connected at any position between the second connection end 131 and the second suspension end 132.
[0053] In addition, in a plurality of layer-stacked sheet-shaped coils 1, adjacent two sheet-shaped coils 1 are arranged at intervals to form a heat dissipation channel 10 between the adjacent two sheet-shaped coils 1. The heat dissipation area of the coil unit can also be increased through the heat dissipation channel 10, and the heat dissipation coefficient of the coil unit can be increased, thereby reducing the temperature rise of the coil unit.
[0054] Among the multiple sheet-shaped coils 1 arranged in a stacked manner, the distance between two adjacent sheet-shaped coils 1 is equal to improve the structural consistency of the entire coil unit. In some embodiments, during the connection of the first connection segments 12 and the second connection segments 13 of the multiple sheet-shaped coils 1 respectively, cardboard can be placed between two adjacent sheet-shaped coils 1. After the multiple first connection segments 12 and the multiple second connection segments 13 are connected, the cardboard is removed to form a preset gap between two adjacent sheet-shaped coils 1. The preset gap between the two sheet-shaped coils 1 forms a heat dissipation channel 10 between two adjacent sheet-shaped coils 1. The preset gap size needs to meet the requirement that air flow can pass through, and the preset gap size can be equal to the thickness size of the cardboard.
[0055] In other embodiments, it is provided that the coil unit includes a support structure. The support structure is located between two adjacent coil bodies 11 in the thickness direction of the strip-shaped wire, that is, between two adjacent sheet-shaped coils 1 in the stacking direction of the multiple sheet-shaped coils 1, so that there is a preset gap for forming a heat dissipation channel 10 between two adjacent coil bodies 11. The size of the preset gap can be ensured by the size of the support structure in the stacking direction of the multiple sheet-shaped coils 1.
[0056] In one embodiment, the support structure may include a dot-shaped glue layer. The dot-shaped glue layer is an insulating glue layer. There are multiple dot-shaped glue layers arranged between two adjacent sheet-shaped coils 1. The multiple dot-shaped glue layers are arranged at intervals in a plane perpendicular to the direction where the winding axis is located. It should be noted that the area of the dot-shaped glue layer should not be too large, and the number of dot-shaped glue layers should not be too many. The multiple dot-shaped glue layers are used to ensure that the gaps between two adjacent sheet-shaped coils 1 are equal everywhere. The adjacent two dot-shaped glue layers are arranged at intervals to form a heat dissipation channel 10 between the adjacent two dot-shaped glue layers. The dot-shaped glue layer can be fixed to the sheet-shaped coil 1 by adhering dot-shaped glue on one of the two adjacent sheet-shaped coils 1.
[0057] In other embodiments, the support structure may further include insulating blocks. The insulating blocks are adhered to one of the two adjacent sheet-shaped coils 1 by means of glue. There are multiple insulating blocks. The adjacent two insulating blocks are arranged at intervals. The size of the insulating blocks in the direction where the winding axis is located is equal to the preset gap size between two adjacent sheet-shaped coils 1. A heat dissipation channel 10 is formed between the adjacent two insulating blocks. The preset gap between two adjacent sheet-shaped coils 1 is ensured by the insulating blocks.
[0058] To avoid short - circuiting between two adjacent coil bodies 11 in the direction of the winding axis, thereby improving the stability and reliability of the coil unit, before multiple sheet - like coils 1 are connected in parallel, the sheet - like coils 1 are subjected to insulation treatment and anti - oxidation treatment. In some embodiments, an insulating layer can be coated on the surface of the sheet - like coil 1 to achieve the effects of insulation and anti - oxidation. In the case of a relatively small current - carrying voltage, only anti - oxidation treatment can be performed on the sheet - like coil 1. For example, an anti - oxidation layer can be formed on the surface of the sheet - like coil 1 by electroplating or fog - tinning.
[0059] Among multiple stacked sheet - like coils 1, the first connection segments 12 of two adjacent sheet - like coils 1 are connected through a solder layer, and the second connection segments 13 of two adjacent sheet - like coils 1 are also connected through a solder layer. In one embodiment, in order to facilitate the connection of two adjacent sheet - like coils 1, solderability treatment also needs to be performed on the first connection segments 12 and the second connection segments 13 on each sheet - like coil 1. For example, after the anti - oxidation and insulation treatment of the sheet - like coil 1, the insulating layers attached to the first suspension end 122 of the first connection segment 12 and the second suspension end 132 of the second connection segment 13 are removed, and then the first suspension end 122 of the first connection segment 12 and the second suspension end 132 of the second connection segment 13 are subjected to tin - plating, nickel - plating or silver - plating treatment to form a solder layer, so as to facilitate the connection of two adjacent first connection segments 12 and two adjacent second connection segments 13 by welding through the solder layer, which helps to ensure the connection reliability of two adjacent sheet - like coils 1.
[0060] In an embodiment where only anti - oxidation treatment needs to be performed on the sheet - like coil 1 and insulation treatment is not required, the entire sheet - like coil 1 can be subjected to fog - tinning or electroplating treatment, so as to ensure that while the sheet - like coil 1 has an anti - oxidation effect, two adjacent first connection segments 12 and two adjacent second connection segments 13 can be connected through a solder layer.
[0061] The embodiment of the present application also discloses a coil winding. The coil winding includes multiple coil units in any of the above - mentioned embodiments, and the winding axes of all coil bodies 11 are coaxial. In an embodiment where the coil body 11 in the coil unit is wound less than one turn, multiple coil units are first connected in series to form a one - turn structure, and then are connected in series with the multiple coil units forming a one - turn structure, so as to form a coil winding with multiple turns. In this way, two adjacent coil units are arranged in the winding direction of the coil body 11, and two adjacent coil units are also arranged at intervals in the direction of the winding axis of the coil body 11.
[0062] In an embodiment where the coil body 11 in the coil unit is wound less than one turn and multiple coil units form a complete one - turn structure after being connected in series in the winding direction, multiple coil units are connected in series to form a single - turn coil winding. In this way, two adjacent coil units are only arranged in the winding direction of the coil body 11.
[0063] In an embodiment where the number of winding turns of the coil body 11 in the coil unit is greater than one turn, a plurality of coil units are arranged in the direction of the winding axis, and the plurality of coil units are connected in series to form a multi-turn coil winding.
[0064] In an embodiment where the number of winding turns of the coil body 11 in the coil unit is one turn, a plurality of coil units are arranged in the direction of the winding axis, and the plurality of coil units can also be connected in parallel to form a single-turn coil winding.
[0065] The current flows in the same direction in each coil unit, all flowing from the first connection section 12 to the second connection section 13. Whether the coil units are arranged in the direction of the winding axis or in the winding direction of the coil body 11, when two adjacent coil units are connected in series, the first connection section 12 of one coil unit is connected to the second connection section 13 of the other coil unit; when two adjacent coil units are connected in parallel, the first connection section 12 of one coil unit is connected to the first connection section 12 of the other coil unit.
[0066] When two adjacent coil units arranged in the winding direction of the coil body 11 are connected in series, the first connection section 12 of one coil unit and the second connection section 13 of the other coil unit can be connected by a solder layer, that is, welded; when two adjacent coil units arranged in the direction of the winding axis of the coil body 11 are connected in parallel or in series, a conductive post can be provided between the two connection sections to be connected, and the conductive post is welded to the two connection sections to be connected respectively to achieve conductive connection between the two connection sections.
[0067] The embodiment of the present application also discloses a magnetic component, which includes a magnetic core component and also includes the coil unit in any of the above embodiments or the coil winding in any of the above embodiments. The magnetic component can be one of electrical components including a magnetic core component and a coil, such as a transformer, an inductor, a magnetic memory, an electromagnetic current collector, a magnetic sensor, a terrain filter, or a current transformer.
[0068] The coil winding or the coil unit in the magnetic component surrounds the magnetic core component. The magnetic core component can include an iron core. The extending direction of the magnetic core component is the direction where the winding axis of the coil body 11 is located, and the cross-sectional shape of the magnetic core component determines the shape formed by enclosing the coil body 11 in the coil winding or the coil unit.
[0069] In an embodiment where a magnetic component includes a magnetic core component and a coil unit, the coil body 11 in the coil unit can be wound one turn, less than one turn, or multiple turns. In an embodiment where the coil body 11 is wound one turn, the coil unit in the magnetic component can have only a single-turn structure; in an embodiment where the coil body 11 is wound less than one turn, the magnetic component further includes a wire or a coil, and the wire or the coil is connected in series with the coil unit to surround the magnetic core component at least one turn, so that the basic magnetic field change requirements are met after the coil unit and the wire or the coil are energized; in an embodiment where the coil body 11 is wound multiple turns, the coil unit in the magnetic component can have a multi-turn structure.
[0070] In an embodiment where a magnetic component includes a magnetic core component and a coil winding, the coil winding can have one turn or multiple turns. The coil winding is wound on the magnetic core component, and after the coil winding is energized, it can meet the conventional magnetic field change requirements.
[0071] Regardless of whether the magnetic component includes a coil winding or a coil unit, the magnetic component can ensure the heat dissipation area of the entire magnetic component through the heat dissipation channel 10 formed by the gap between two adjacent sheet coils 1 in the coil unit, thereby increasing the heat transfer coefficient of the magnetic component and reducing the temperature rise; it can also reduce the contact resistance of the entire coil winding or coil unit through multiple parallel sheet coils 1 while ensuring good contact of each connection section, thereby reducing the DC loss of the entire magnetic component; and in the high-frequency state, the coil unit or coil winding can have multiple parallel sheet coils 1 to reduce the skin effect, thereby reducing the AC loss of the entire magnetic component.
[0072] Taking the cross-inductor voltage regulator as an example, please refer to Figure 5 , in the prior art, the cross-inductor voltage regulator includes a housing magnetic core 21, a middle column magnetic core 22, an outer coil 23, and an inner coil 24. The outer coil 23 is a square coil structure, which is formed by bending a strip-shaped copper wire with a cross-sectional size of 1.2 mm × 3 mm after fog tinning. The inner coil 24 is also a square coil structure, which is formed by bending a flat enameled wire with a cross-sectional size of 0.3 mm × 3 mm. The middle column magnetic core 22 serves as the magnetic core component of the inner coil 24 and is located in the surrounding space of the inner coil 24. The inner coil 24 and the middle column magnetic core 22 serve as the magnetic core components of the outer coil 23 and are located in the surrounding space of the outer coil 23. The outer coil 23, the inner coil 24, and the middle column magnetic core 22 are all located in the housing magnetic core 21. The housing magnetic core 21 and the middle column magnetic core 22 are both insulated by spraying. The outer coil 23 and the inner coil 24 are separated by an insulating layer, and the inner and outer coils are arranged at intervals with the insulating layer. In this structure of the cross-inductor voltage regulator, both the outer coil 23 and the inner coil 24 have little contact with the outside air, and it is difficult to form air flow inside.
[0073] For the cross-inductor voltage regulator structure improved by the solution of the present application, please refer to Figure 6, the outer coil 23 is replaced by coil units. Each coil unit includes six sheet-shaped coils 1 arranged in parallel. Since the cross-inductor voltage regulator is vertically welded to the PCB board and the hot air flow moves from the PCB board towards the cross-inductor voltage regulator in the direction of the PCB board and the cross-inductor voltage regulator arrangement, multiple sheet-shaped coils 1 in the coil unit are arranged in layers in the direction of the winding axis of the coil body 11. A preset gap of 0.05 mm is left between adjacent two sheet-shaped coils 1, so that the hot air flow can pass through the gap between adjacent two sheet-shaped coils 1 in the coil unit. Thus, a heat dissipation channel 10 is formed within the cross-inductor voltage regulator, which can reduce the skin effect of the outer coil in the cross-inductor voltage regulator and greatly reduce the temperature of the cross-inductor voltage regulator at the same time.
[0074] Specifically, after passing 10 A of alternating current through the outer coil 23 of the cross-inductor voltage regulator in the prior art in Figure 5 and the coil unit serving as the outer coil in the improved cross-inductor voltage regulator in Figure 6 respectively, the resistance values of the two outer coils are measured at different frequencies. Please refer to the following table. Table 1 shows the resistance values of the outer coil 23 of the cross-inductor voltage regulator in the prior art in Figure 5 after passing 10 A of alternating current at different frequencies, and Table 2 shows the resistance values of the coil unit serving as the outer coil in the improved cross-inductor voltage regulator in Figure 6 after passing 10 A of alternating current at different frequencies. From the data in the table, it can be obtained that as the frequency increases, the difference between the resistance value of the coil unit serving as the outer coil in the improved cross-inductor voltage regulator and the resistance value of the outer coil 23 in the cross-inductor voltage regulator of the prior art becomes larger and larger. And in the high-frequency state, the resistance value of the coil unit serving as the outer coil in the improved cross-inductor voltage regulator is smaller than the resistance value of the outer coil 23 in the cross-inductor voltage regulator of the prior art. From this, it can be concluded that the magnetic component using the coil unit protected by this application has a smaller resistance value, lower loss, and higher efficiency in the high-frequency state, and can meet higher power application scenarios.
[0075]
[0076] Please refer to Figure 7 and Figure 8 , in Figure 5 the outer coil 23 of the cross-inductor voltage regulator in the prior art and Figure 6In the improved cross-inductor voltage regulator, 50 A of direct current is respectively passed through the coil units serving as the outer coils. Under the condition that the ambient temperature is 25 °C, the temperature of the cross-inductor voltage regulator is detected by infrared rays. It is found that the lowest temperature value on the cross-inductor voltage regulator of the prior art is 62.328 °C, and the highest temperature value is 73.838 °C. While the lowest temperature value on the improved cross-inductor voltage regulator is 53.735 °C, and the highest temperature value is 61.77 °C. From this, it can be concluded that the magnetic component adopting the coil unit protected by this application has a larger heat dissipation area and a lower temperature rise, which helps to reduce the aging failure rate of the magnetic component at high temperature and helps to extend the service life of the magnetic component.
[0077] The above uses specific examples to elaborate on the present utility model, which is only used to help understand the present utility model and is not intended to limit the present utility model. For those skilled in the technical field to which the present utility model belongs, according to the idea of the present utility model, several simple deductions, deformations or substitutions can also be made.
Claims
1. A coil monomer, characterized in that, It includes a plurality of sheet-shaped coils, the sheet-shaped coils are formed by winding a strip-shaped wire, the sheet-shaped coil includes a coil body, a first connection section and a second connection section, the first connection section and the second connection section are respectively connected to both ends in the winding direction of the coil body, and the plurality of sheet-shaped coils are stacked in the thickness direction of the strip-shaped wire, and adjacent two sheet-shaped coils are arranged at intervals to form a heat dissipation channel, and the first connection sections of all the sheet-shaped coils are connected, and the second connection sections of all the sheet-shaped coils are connected.
2. The coil unit according to claim 1, wherein The direction where the winding axis of the coil body is located is the same as the thickness direction of the strip-shaped wire; or, the direction where the winding axis of the coil body is located is the same as the width direction of the strip-shaped wire.
3. The coil unit according to claim 1, wherein The coil body has an open-loop structure, and the strip-shaped wire is wound once to form the coil body.
4. The coil unit according to claim 3, characterized in that, The direction where the winding axis of the coil body is located is the same as the thickness direction of the strip-shaped wire, and the dimension of the coil body in the direction where the winding axis is located is equal to the thickness dimension of the strip-shaped wire; or, the direction where the winding axis of the coil body is located is the same as the width direction of the strip-shaped wire, and the dimension of the coil body in the direction where the winding axis is located is equal to the width dimension of the strip-shaped wire.
5. The coil unit according to claim 3, characterized in that, The first connection section and the second connection section are arranged at intervals in the winding direction of the coil body; The direction where the winding axis of the coil body is located is the same as the thickness direction of the strip-shaped wire, and the dimension of the sheet-shaped coil in the direction where the winding axis is located is equal to the thickness dimension of the strip-shaped wire; or, the direction where the winding axis of the coil body is located is the same as the width direction of the strip-shaped wire, and the dimension of the sheet-shaped coil in the direction where the winding axis is located is equal to the width dimension of the strip-shaped wire.
6. The coil unit according to claim 1, wherein The orientation of the first connection section is opposite to the orientation of the second connection section; or, the orientation of the first connection section is the same as the orientation of the second connection section, and the first connection section and the second connection section are arranged at intervals.
7. The coil unit according to any one of claims 1 to 6, characterized in that The first connection section has a first connection end and a first suspension end located at both ends thereof, the first connection end is connected to the coil body, and two adjacent first suspension ends in the thickness direction of the strip-shaped wire are connected; and / or, The second connection section has a second connection end and a second suspension end located at both ends thereof, the second connection end is connected to the coil body, and two adjacent second suspension ends in the thickness direction of the strip-shaped wire are connected.
8. The coil unit according to any one of claims 1 to 6, characterized in that, In the thickness direction of the strip-shaped wire, two adjacent first connection sections are connected by a solder layer, and / or, two adjacent second connection sections are connected by a solder layer.
9. The coil unit according to any one of claims 1 to 6, characterized in that, An anti-oxidation layer is attached to the surface of the sheet-shaped coil.
10. The coil unit according to any one of claims 1 to 6, characterized in that, The coil unit includes a support structure, and the support structure is located between two adjacent coil bodies in the thickness direction of the strip-shaped wire, so that a preset gap for forming the heat dissipation channel is provided between two adjacent coil bodies.
11. A coil winding, characterized in that, Comprising a plurality of coil units as described in any one of claims 1 to 10, the winding axes of all the coil bodies are coaxial, two adjacent coil bodies are arranged in the winding direction of the coil body and / or in the direction where the winding axis is located, and all the coil units are connected in series and / or in parallel.
12. A magnetic component, characterized in that, Comprising a magnetic core member, further comprising a coil unit as described in any one of claims 1 to 10 or a coil winding as described in claim 11.