Flat wire pin direct connection type magnetic element
By adopting flat line pin direct-connected magnetic components with flat line winding and insulation design, the problems of strict winding space, high labor costs and poor heat dissipation effects in the prior art are solved, and a flat design with higher current load-bearing capacity and lower cost are achieved.
Patent Information
- Application Number
- CN202421646909.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-07-12
- Publication Date
- 2025-07-22
- Estimated Expiration
- 2034-07-12
AI Technical Summary
In the prior art, PFC inductors wound with circular copper wire have strict winding space requirements, high labor costs, poor heat dissipation effect and large space occupancy, making it difficult to meet the flat design needs of new energy vehicle modules.
The coil is wound with a flat wire, combined with an insulating sleeve and an insulating gasket, and the lead wire is directly bent as a pin, eliminating the connection terminal welding process, and winding the wire using a circular shaft push-winding method. The shell is designed as a bracket to improve heat dissipation. The core is electrically isolated by a Nome paper sleeve.
It improves current carrying capacity, reduces labor and material costs, enhances product reliability, meets flat design requirements, and improves heat dissipation effect.
Smart Images
Figure CN223140537U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a flat wire pin directly connected magnetic component, belonging to the technical field of electronic components. Background Art
[0002] With more and more local designs in modern power technologies, especially in the field of new energy electric vehicles, the design cost requirements for the solutions themselves are getting higher and higher. A large number of capacitors are used in switching power supplies. Capacitors can charge and discharge themselves, and are prone to generating high-frequency pulse voltages (also known as higher harmonics), which can cause input current distortion and even interfere with the normal operation of the power grid.
[0003] To reduce this interference, a PFC inductor is required. When alternating current passes through the PFC inductor, a magnetic field is generated, which reduces the rate of change of the current, thereby reducing the higher harmonics in the circuit, smoothing the current in the circuit, reducing the ineffective power loss, and improving the power factor (PF value, the ratio of active power to apparent power) of the power supply. The presence of the PFC inductor greatly improves the stability of the circuit, and significantly improves the power factor, power supply efficiency, and electromagnetic interference. It has become an essential part of modern switching power supplies. In the field of electric vehicles, a water-cooling method is adopted, and the on-vehicle PFC inductor is placed in an aluminum or plastic cavity and filled with glue with a high thermal conductivity coefficient to further improve the power density, so as to optimize the overall design and cost of the product.
[0004] The conventional structure of a three-phase PFC inductor usually adopts the method of winding round copper wires on a magnetic core (such as Figure 1 and Figure 2 ) or the method of winding round copper wires on an EQ-type magnetic core (such as Figure 3 ).
[0005] Using round copper wires has strict requirements for the winding space of the magnetic core, and the wire coil needs to be wound manually or semi-manually. Currently, as the design power of the whole machine is getting larger and the input current is continuously increasing, the cross-sectional area of the wire also needs to be larger. When designing and selecting the current density of the copper wire, if it is designed based on round copper wire, the current density will be limited, and it will be very difficult to wind multiple strands of wire in terms of technology, increasing the labor cost. Multiple turns of round wire need to be closely arranged layer by layer. Due to the large number of layers, it is not easy for the glue to flow into the inside of the wire coil during potting, and the heat dissipation effect of the product is poor.
[0006] In addition, after using the magnetic core to wind the product, the outer wires are stacked, occupying a large space, making the overall size of the product relatively large, not conforming to the flat design concept in new energy vehicle modules, and also occupying a certain amount of extra space for other components in the whole machine. Summary of the Utility Model
[0007] In view of this, the utility model proposes a flat wire pin directly connected magnetic component to solve the problems existing in the above-mentioned prior art.
[0008] A flat wire pin - directly - connected magnetic component, comprising a housing, a magnetic core, a coil wound with flat wire, an insulating sleeve and an insulating gasket; the magnetic core is accommodated in the housing, and an insulating sleeve is sleeved outside the middle column of the magnetic core; the coil is sleeved on the middle column of the magnetic core with the insulating sleeve, and insulating gaskets are respectively attached to the axial two ends of the coil; wire grooves are provided on the housing, and the lead - out wires of the coil are bent and then attached to the wire grooves and led out to the outside of the housing to serve as the pins of the magnetic component.
[0009] The beneficial effects of the technical solution of the present utility model are as follows: Compared with the circular wire winding in existing products, the present utility model uses flat wire to wind the coil, and a larger cross - sectional area of copper wire can be selected, so that the current that the product itself can withstand is increased; the winding can be completed by using the method of pushing and winding on a circular shaft on the winding equipment, saving labor costs. In addition, the present utility model directly bends, punches holes and strips the lead - out wires to serve as pins, without using additional connection terminals, not only saving the process of welding with the connection terminals, but also greatly reducing the material cost and labor cost of the product, and improving the reliability and product competitiveness.
[0010] Further, the lead - out wires of the coil are bent along a first direction at the upper end of the wire groove, then led from the wire groove to the lower end of the wire groove and bent along a second direction, and holes are punched in the part bent along the second direction.
[0011] Further, the bending along the first direction is a downward bending along the upper end of the wire groove, so that the lead - out wire is led to the lower end of the wire groove along the bottom of the wire groove; the bending along the second direction is an outward bending relative to the housing.
[0012] Further, a fillet or chamfer design is carried out at the joint between the upper end of the wire groove and the lead - out wire. In this further technical solution, this fillet or chamfer design can prevent the lead - out wire from being cut by the right - angled edge of the housing.
[0013] Further, the lower end of the wire groove is formed with an end perpendicular to the bottom of the groove for placing the part of the lead - out wire bent along the second direction. In this further technical solution, the right - angled part formed by this end and the bottom of the groove is exactly suitable for accommodating the part of the lead - out wire bent along the second direction, playing a role in supporting and fixing the pin.
[0014] Further, the housing is a plastic housing, which is provided in a bracket shape with an empty top and an empty bottom and a hollow part on the side wall. In this further technical solution, such a bracket - shaped housing is more conducive to the heat dissipation of the product.
[0015] Further, the wire groove is connected to the upper part of one side wall of the outer shell, and there is a gap between the back surface of the wire groove and the one side wall. In this further technical solution, the reserved gap is beneficial to heat dissipation and avoids the heat dissipation of the coil inside the outer shell being blocked by the wire groove at this side wall.
[0016] Further, the magnetic core includes a first magnetic core and a second magnetic core with the same structure, and the first magnetic core and the second magnetic core are assembled by butt joint and gluing.
[0017] Further, the insulating sleeve is a Nomex paper sleeve.
[0018] Further, the insulating gasket is a ring shape consistent with the shape of the coil.
[0019] In a further technical solution, the Nomex paper sleeve and the insulating gasket ensure the basic insulation between the coil and the magnetic core and achieve electrical isolation. Description of the Drawings
[0020] Figure 1 is and Figure 2 are two structures of the existing three-phase PFC inductor using magnetic wire winding.
[0021] Figure 3 is a schematic diagram of the existing PFC inductor using an EQ-type magnetic core to wind round copper wire.
[0022] Figure 4 is a schematic diagram of the flat wire pin directly connected magnetic component in Embodiment 1 of the present invention.
[0023] Figure 5 is Figure 4 a cross-sectional view of the side view angle of the flat wire pin directly connected magnetic component shown.
[0024] Figure 6 is Figure 4 an exploded view of the structure of the flat wire pin directly connected magnetic component shown.
[0025] Figure 7 is a schematic diagram of the flat wire pin directly connected magnetic component in Embodiment 2 of the present invention.
[0026] Figure 8 is Figure 7 a cross-sectional view of the front view angle of the flat wire pin directly connected magnetic component shown.
[0027] Figure 9 is a schematic diagram of the outer shell of the flat wire pin directly connected magnetic component of the present invention.
[0028] Figure 10 is a schematic diagram of the coil pins of the flat wire pin directly connected magnetic component of the present invention not being at the same height. Detailed implementation mode
[0029] The present utility model will be further described below in conjunction with the accompanying drawings, specific implementation modes, and embodiments. The purpose of providing the embodiments is only for illustration and not for any limitation.
[0030] In addition, for the spatial orientation terms such as "upper", "lower", "top", "bottom", etc. used in the description of the technical solution of the present utility model, they are used to facilitate the description of the relative positional relationship between the components of the product, and do not represent that the product has only the orientation shown in the figure. During the actual use process, as the orientation of the product changes, the spatial-related descriptions used to describe its orientation should also be explained in a similar way.
[0031] Embodiment 1
[0032] Embodiment 1 of the present utility model provides a flat wire pin direct-connected magnetic component, especially an in-vehicle PFC inductor. Please refer to Figures 4 to 6 , in this example, three identical inductor units are assembled in the plastic housing 1 of the magnetic component. The inductor unit includes a magnetic core 2, a coil 3 wound with flat wire, an insulating sleeve 4, and an insulating gasket 5; the magnetic core 2 is accommodated in the housing 1, and an insulating sleeve 4 is sleeved outside the middle column of the magnetic core; the coil 3 is sleeved on the middle column of the magnetic core with the insulating sleeve 4, and insulating gaskets 5 are respectively attached to both axial ends of the coil 3; with joint reference to Figure 9 , wire grooves 11 are provided on the housing 1, and the lead wires 31 of the coil 3 are bent and attached to the wire grooves 11 and led out to the outside of the housing as the pins of the magnetic component, without the need to additionally weld connection terminals.
[0033] Continue to refer to Figure 9 , the housing 1 is provided in a bracket shape with an empty top and an empty bottom and a hollow part on the side wall. The wire groove 11 is connected to the upper part of one side wall of the housing, and there is a gap between the back of the wire groove 11 and the side wall. Specifically, each housing corresponding to the inductor unit contains two wire grooves 11, which are respectively used to accommodate the two lead wires of the coil of one inductor unit. Refer to Figure 4 , the lead wire 31 of the coil 3 is bent downward from the upper end of the wire groove 11, led along the wire groove to the lower end of the wire groove, and then bent outward relative to the housing (or relative to the wire groove), and a hole is punched in the outwardly bent part 311. Refer to Figure 4 and Figure 9 , preferably, the joint 12 between the upper end of the wire groove 11 and the lead wire is designed with a fillet or chamfer; the lower end of the wire groove 11 is formed with an end 13 perpendicular to the bottom of the wire groove for placing the part 311 where the lead wire is bent outward relative to the housing and punched.
[0034] Continue to refer to Figures 4 to 6, the magnetic core 2 includes two EQ magnetic cores 21 and 22 with the same structure. After the coil 3 is wound by the method of circular shaft pushing winding on the winding equipment, the lead wires are bent according to the preset shape, punched at the pin ends 32, and then peeled at the pin ends (removing the outer insulating coating of the copper wire). During assembly, first, the insulating sleeve 4 (such as Nomex sleeve) is nested into the inner hollow part of the coil 3, and then the two are assembled with the magnetic cores 21 and 22, so that the magnetic cores 21 and 22 are butt-assembled. At the same time, the insulating sleeve 4 is sleeved on the middle column 23 of the magnetic core after the two magnetic cores are butted, and the coil 3 is sleeved on the middle column of the magnetic core sleeved with the insulating sleeve. Annular insulating gaskets 5 are respectively attached to the axial two ends of the coil 3 to be insulated from the two magnetic cores respectively, and the butt joint of the two magnetic cores is bonded with glue 6. The assembled magnetic core and coil are placed in the shell, and the lead wires bent by the jig are placed in the wire groove to form Figure 5 the assembled structure shown.
[0035] It should be understood that the wire ends of the two lead wires of the coil of each inductance unit can be at the same height as shown in Figure 4 or not at the same height as shown in Figure 10 , so that the magnetic core element can adapt to different placement forms, including but not limited to the horizontal, vertical placement, longitudinal or transverse placement forms of the magnetic core.
[0036] Embodiment 2
[0037] Embodiment 2 of the present utility model provides a flat wire pin directly connected magnetic element as shown in Figure 7 and Figure 8 . Its structural composition is substantially the same as that of Embodiment 1, and the main difference lies in the different placement directions of the magnetic core in the shell. In Embodiment 1, the axial direction of the middle column of the magnetic core and the axial direction of the coil are parallel to the length direction of the shell, while in Embodiment 2, the axial direction of the middle column of the magnetic core and the axial direction of the coil are perpendicular to the length direction of the shell.
[0038] It should be understood that the magnetic elements including three inductance units shown in Embodiment 1 and Embodiment 2 are only examples. There can also be only 1 or 2 inductance units, or more than 3 inductance units. The present utility model does not limit this. In addition, it should be understood that the EQ magnetic cores in Embodiment 1 and Embodiment 2 are only exemplary, and the present utility model should not be limited to the EQ type magnetic core.
[0039] The above content is a further detailed description of the present utility model in combination with specific preferred embodiments. It cannot be determined that the specific implementation of the present utility model is only limited to these descriptions. For those skilled in the technical field to which the present utility model belongs, without departing from the concept of the present utility model, several equivalent substitutions or obvious variations can be made, and if the performance or use is the same, they should all be regarded as belonging to the protection scope of the present utility model.
Claims
1. A flat wire pin directly connected magnetic component, characterized in that: It includes a housing, a magnetic core, a coil wound with flat wires, an insulating sleeve and an insulating gasket; The magnetic core is accommodated in the housing, and an insulating sleeve is sleeved outside the middle column of the magnetic core; the coil is sleeved on the middle column of the magnetic core sleeved with the insulating sleeve, and insulating gaskets are respectively attached to both axial ends of the coil; A wire groove is provided on the housing, and the lead wires of the coil are bent and then attached to the wire groove and led out to the outside of the housing to serve as the pins of the magnetic component.
2. The flat wire pin directly connected magnetic component according to claim 1, wherein: The lead wires of the coil are bent along a first direction at the upper end of the wire groove, then led from the wire groove to the lower end of the wire groove and bent along a second direction, and holes are punched in the part bent along the second direction.
3. The flat wire pin - directly - connected magnetic component according to claim 2, wherein: The bending along the first direction is to bend downward along the upper end of the wire groove so that the lead wire is led to the lower end of the wire groove along the bottom of the wire groove; the bending along the second direction is to bend outward relative to the housing.
4. The flat wire pin directly connected magnetic component according to claim 3, wherein: A fillet or chamfer design is carried out at the joint between the upper end of the wire groove and the lead wire.
5. The flat wire pin directly connected magnetic component according to claim 3, wherein: The lower end of the wire groove is formed with an end perpendicular to the bottom of the groove for placing the part of the lead wire bent along the second direction.
6. The flat wire pin directly connected magnetic component according to claim 1, wherein: The housing is a plastic housing, which is provided in a bracket shape with an empty top and an empty bottom and a hollow part on the side wall.
7. The flat wire pin - directly - connected magnetic component according to claim 6, characterized in that: The wire groove is connected to the upper part of one side wall of the housing, and there is a gap between the back of the wire groove and the one side wall.
8. The flat wire pin directly connected magnetic component according to claim 1, wherein: The magnetic core includes a first magnetic core and a second magnetic core with the same structure, and the first magnetic core and the second magnetic core are assembled by docking and gluing.
9. The flat wire pin - directly connected magnetic component according to claim 1, wherein: The insulating sleeve is a Nomex paper sleeve.
10. The flat wire pin - directly - connected magnetic component according to claim 1, wherein: The insulating gasket is an annular shape consistent with the shape of the coil.