Power inductor

Abstract

The utility model relates to a power inductor, which comprises a magnetic ring, the magnetic ring is in a circular ring shape, the cross section of the magnetic ring along the circumferential direction is in a circular shape or an oval shape, and the magnetic ring is integrally formed; the coil is wound on the magnetic ring by adopting a flat enameled copper wire, and a gap is reserved between turns of the coil. According to the power inductor disclosed by the utility model, the magnetic ring is annular, the cross section along the circumferential direction is circular or elliptical, and the coil is smooth and free from resistance in the winding process, so that automatic winding equipment can be adopted for mass production to reduce the production cost; the magnetic ring is integrally formed, so that complex procedures such as high-precision cutting and bonding are avoided, and the production cost is reduced; the coil is formed by winding the flat enameled copper wires, and gaps are formed between turns of the coil, so that efficient heat dissipation can be realized.

Description

Technical Field

[0001] The utility model relates to the technical field of inductors, in particular to a power inductor. Background Art

[0002] In the PFC circuit of a power module, the power inductor is an important and expensive component. Its high frequency and integration trend leads to significant temperature rise problems. Currently, the mainstream power inductor structures are mainly divided into the following three types:

[0003] One is to use a magnetic ring with a rectangular cross-section along the circumference, and wind the enameled copper wire with a circular cross-section on the magnetic ring. In order to increase the inductance, multiple layers need to be wound. There is no gap between the coil and the magnetic ring, and there is no gap between the turns of the coil. The temperature of the copper wire wound in the inner layer cannot be dissipated, resulting in a temperature increase. In addition, manual winding is required, and the production cost is very high.

[0004] The second method is to use a magnetic ring with a rectangular cross-section along the circumference, cut the magnetic ring in half, and wind a flat enameled copper wire into a coil. The coil is then placed on the cut magnetic ring, and finally the magnetic ring and coil are fixed by gluing and adding a locking steel band. The flat enameled copper has a large cross-sectional area, which can ensure that the inductance meets the requirements, and there is a gap between the turns of the coil, so the heat dissipation effect is good and the temperature rise is low. However, this structure requires high-precision cutting and bonding, otherwise it will cause the inductance to drop or the magnetic core to damage, which increases production costs.

[0005] The third method is to use the magnetic column splicing method, wind the flat enameled copper wire into a coil, then put the coil on the magnetic column, and then use a cover plate to splice the two ends of the magnetic column and fix them with glue. The effect of this method is similar to cutting the magnetic ring in half and then splicing it together. It also has the problems of difficult assembly and high production cost. Utility Model Content

[0006] The purpose of the utility model is to provide a power inductor to solve the problem that existing power inductors cannot simultaneously meet the requirements of good heat dissipation effect and low production cost.

[0007] To achieve this purpose, the present invention adopts the following technical solutions:

[0008] A power inductor, comprising:

[0009] A magnetic ring, wherein the magnetic ring is in a circular ring shape, the cross section of the magnetic ring along the circumference is circular or elliptical, and the magnetic ring is integrally formed;

[0010] The coil is wound on the magnetic ring using flat enameled copper wire, with gaps left between turns of the coil.

[0011] Preferably, the cross-section of the coil along the circumferential direction is annular, and a gap is left between the coil and the magnetic ring.

[0012] Preferably, the power inductor is packaged in a vertical or horizontal manner;

[0013] When the power inductor adopts a vertical package and the cross-section of the magnetic ring along the circumferential direction is elliptical, the magnetic ring abuts against the coil, and the major axis direction of the ellipse is parallel to the radial direction of the magnetic ring;

[0014] When the power inductor adopts a horizontal package and the cross-section of the magnetic ring along the circumferential direction is elliptical, the magnetic ring abuts the coil, and the major axis direction of the ellipse is parallel to the axial direction of the magnetic ring.

[0015] Preferably, in the circumferential direction of the magnetic ring, the magnetic ring has a winding section and a fixed section, and the coil is wound around the winding section.

[0016] Preferably, the power inductor further includes a base, and the magnetic ring is fixed on the base by epoxy resin.

[0017] Preferably, the base is made of high-temperature resistant and flame-retardant insulating material.

[0018] Compared with the prior art, the present invention has the following beneficial effects: the magnetic ring is in a circular ring shape, and the cross-section along the circumferential direction is circular or elliptical. The coil winding process is smooth and free of resistance, so it can be mass-produced using automated winding equipment to reduce production costs; the magnetic ring is integrally formed, avoiding complex processes such as high-precision cutting and bonding, thereby reducing production costs; the coil is wound with flat enameled copper wire, and there is a gap between the turns of the coil, so it can dissipate heat efficiently. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] The structures, proportions, sizes, etc. depicted in the drawings of this specification are only used to match the contents disclosed in this specification so as to facilitate understanding and reading by those familiar with this technology. They are not intended to limit the conditions under which the present invention can be implemented, and therefore have no substantive technical significance. Any structural modifications, changes in proportional relationships, or adjustments in size, without affecting the efficacy and objectives that can be achieved by the present invention, should still fall within the scope of the technical contents disclosed in the present invention.

[0021] Figure 1 Schematic diagram of the structure of the power inductor in this embodiment;

[0022] Figure 2 FIG. 4 is a schematic cross-sectional view of the power inductor along the circumferential direction in this embodiment.

[0023] Description of the accompanying drawings: 10, magnetic ring; 20, coil. DETAILED DESCRIPTION

[0024] In order to make the purpose, features, and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0025] In the description of the present invention, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of the present invention and simplify the description. They are not intended to indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally located component.

[0026] The technical solution of the present invention will be further described below with reference to the accompanying drawings and through specific implementation methods.

[0027] Reference Figures 1 to 2 The power inductor disclosed in this embodiment includes: a magnetic ring 10 and a coil 20. The magnetic ring 10 is in a circular ring shape, and the cross-section of the magnetic ring 10 along the circumferential direction is circular or elliptical, and the magnetic ring 10 is formed in one piece; the coil 20 is wound on the magnetic ring 10 using flat enameled copper wire, and gaps are left between turns of the coil 20.

[0028] like Figure 1 as well as Figure 2 As shown in Figures A1 to A4, the magnetic ring 10 is in the shape of a ring, and the cross-section along the circumferential direction is circular or elliptical. The coil 20 is wound smoothly without resistance, so it can be mass-produced using automated winding equipment to reduce production costs. The magnetic ring 10 is integrally formed, avoiding complex processes such as high-precision cutting and bonding, thereby reducing production costs. The coil 20 is wound with flat enameled copper wire, and there is a gap between the turns of the coil 20, so it can dissipate heat efficiently.

[0029] The cross-section of the coil 20 along the circumference is annular, which facilitates mass production using automated winding equipment to reduce production costs. A gap is left between the coil 20 and the magnetic ring 10 to further improve heat dissipation. The winding process of the automated winding equipment includes the following steps:

[0030] S1: Install the annular integrally formed magnetic ring 10 on a fixing device of the winding equipment to ensure that the magnetic ring 10 is stable and immovable during the winding process;

[0031] S2: Setting the parameters of the coil 20: Input the number of turns of the coil 20, the gap between turns, and the specifications of the flat enameled copper wire into the control system of the winding equipment to ensure the accuracy of the winding;

[0032] S3: Fix the starting point of the coil 20: Fix the starting end of the flat enameled copper wire on the magnetic ring 10 by a robotic arm or other fixing device to ensure that the wire end is stable;

[0033] S4: Rotating magnetic ring 10: After the device is started, the magnetic ring 10 rotates at a set speed. During the rotation, the flat enameled copper wire is wound around the magnetic ring 10;

[0034] S5: Control the gap between turns: Use a precise wire device and tension control system to ensure that the set gap is maintained between each turn of the coil. This is achieved through a servo motor and precision guide rails to ensure that each turn is wound according to the predetermined position.

[0035] S6: Fix the end of coil 20: When the set number of turns is reached, the device will automatically fix the end of the last turn of flat enameled copper wire to ensure that coil 20 will not loosen;

[0036] S7: Wire cutting: Cut off excess copper wire and process the wire ends to prevent short circuit or other problems;

[0037] S8: Remove the power inductor: The automated robot removes the wound power inductor from the fixture and places it in the designated finished product area.

[0038] Power inductors are packaged in vertical or horizontal packaging;

[0039] like Figure 2 As shown in Figure A3, when the power inductor is packaged vertically and the circumferential cross-section of the magnetic ring 10 is elliptical, the magnetic ring 10 abuts the coil 20, and the long axis of the ellipse is parallel to the radial direction of the magnetic ring 10. This means that in the vertical state, only the top and bottom ends of the magnetic ring 10 abut the coil 20, preliminarily securing the coil 20 and the magnetic ring 10 to facilitate the next packaging operation. At the same time, the contact area between the coil 20 and the magnetic ring 10 is minimized, which is beneficial for heat dissipation.

[0040] like Figure 2 As shown in Figure A4, when the power inductor is packaged horizontally and the circumferential cross-section of the magnetic ring 10 is elliptical, the magnetic ring 10 abuts the coil 20, and the long axis of the ellipse is parallel to the axial direction of the magnetic ring 10. This means that in the horizontal position, only the top and bottom ends of the magnetic ring 10 abut the coil 20, preliminarily securing the coil 20 and the magnetic ring 10 to facilitate the next packaging operation. At the same time, the contact area between the coil 20 and the magnetic ring 10 is minimized, which is beneficial for heat dissipation.

[0041] The magnetic ring 10 has a winding section and a fixed section in the circumferential direction of the magnetic ring 10 , and the coil 20 is wound around the winding section.

[0042] Furthermore, the power inductor further includes a base, and the magnetic ring 10 and the coil 20 are fixed on the base by epoxy resin.

[0043] Furthermore, the base is made of high-temperature resistant and flame-retardant insulating material to ensure safety and reliability in high-temperature environments.

[0044] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments can still be modified, or some of the technical features thereof can be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A power inductor, characterized in that: include: A magnetic ring (10), the magnetic ring (10) is in a circular ring shape, the cross section of the magnetic ring (10) along the circumferential direction is circular or elliptical, and the magnetic ring (10) is integrally formed; A coil (20) is wound on the magnetic ring (10) using a flat enameled copper wire, with gaps left between turns of the coil (20).

2. A power inductor according to claim 1, characterized in that: The cross-section of the coil (20) along the circumferential direction is annular, and a gap is left between the coil (20) and the magnetic ring (10).

3. The power inductor according to claim 2, characterized in that: The power inductor adopts vertical packaging or horizontal packaging; When the power inductor adopts a vertical package and the cross-section of the magnetic ring (10) along the circumferential direction is elliptical, the magnetic ring (10) abuts against the coil (20), and the long axis direction of the ellipse is parallel to the radial direction of the magnetic ring (10); When the power inductor adopts a horizontal package and the cross-section of the magnetic ring (10) along the circumferential direction is elliptical, the magnetic ring (10) abuts against the coil (20), and the long axis direction of the ellipse is parallel to the axial direction of the magnetic ring (10).

4. The power inductor according to claim 1, characterized in that: In the circumferential direction of the magnetic ring (10), the magnetic ring (10) has a winding section and a fixed section, and the coil (20) is wound around the winding section.

5. The power inductor according to claim 1, characterized in that: It also includes a base, and the magnetic ring (10) and the coil (20) are fixed on the base by epoxy resin.

6. The power inductor according to claim 5, characterized in that: The base is made of high-temperature resistant and flame-retardant insulating material.

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