Novel filter inductor structure

Abstract

The utility model relates to the technical field of inductor structures, in particular to a novel filter inductor structure which comprises a magnetic circuit middle column, a coil, a rigid base and a magnetic core side column. The magnetic circuit middle column is transversely mounted at the front part of the magnetic core side column, the coil is wound on the magnetic circuit middle column, the magnetic core side column is vertically mounted on the top surface of the rigid base, and the front part of the magnetic core side column and the top surface of the rigid base are encircled to form a coil setting position with an open front side; the rigid base is provided with at least one coil outgoing line through hole, and an outgoing line of the coil vertically penetrates through the coil outgoing line through hole to be led out; the filter inductor solves the problem that a traditional filter inductor structure cannot be suitable for application scenes of large current, high voltage or need of multi-path inductor outgoing lines.

Description

Technical Field

[0001] The utility model relates to the technical field of inductor structures, in particular to a novel filtering inductor structure. Background Art

[0002] In the field of power electronics, filter inductors, as key components, are widely used in various circuits to suppress current fluctuations and noise, ensuring stable operation of equipment. Traditional filter inductor structures typically employ a magnetic core design with a center leg and at least two side legs. These legs are typically arranged vertically to form a stable magnetic field structure. In this design, copper wire is wound around the center leg of the core to form a coil, which is located between the center leg and the side legs. To enhance heat dissipation, gaps are often designed between the side legs to more effectively dissipate heat generated by the coil.

[0003] However, when this traditional filter inductor structure is applied to high-current, high-voltage, or multi-path inductor applications, its limitations become apparent. To meet the demands of high-current transmission, the copper wire diameter must be increased. This directly requires lengthening the center and side legs of the magnetic core and expanding the size of the core frame to accommodate the larger coils. This adjustment process is not only technically challenging but also increases material consumption, thereby increasing production costs.

[0004] Even more challenging is the fact that large-diameter copper wire is prone to deviation during lateral winding due to its own weight, making the winding process difficult and uncontrollable. Furthermore, bending the coil's outlet after winding presents significant challenges, as large-diameter copper wire is prone to stress concentration during bending, increasing the risk of breakage.

[0005] In summary, the design limitations of traditional filter inductor structures when facing high current, high voltage, and multi-line requirements lead to significant increases in manufacturing costs, while also posing a potential threat to production efficiency and product quality. Therefore, a new filter inductor structure is urgently needed to overcome the shortcomings of existing technologies and meet the growing demand for filter inductor performance in power electronic equipment. Utility Model Content

[0006] In view of the above-mentioned defects, the purpose of the present invention is to propose a new filter inductor structure, which solves the problem that the traditional filter inductor structure is not suitable for application scenarios with high current, high voltage or requiring multiple inductor output lines.

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

[0008] A novel filter inductor structure includes a magnetic circuit center column, a coil, a rigid base, and a magnetic core side column; the magnetic circuit center column is horizontally mounted on the front of the magnetic core side column, the coil is wound around the magnetic circuit center column, and the magnetic core side column is vertically mounted on the top surface of the rigid base. The front of the magnetic core side column and the top surface of the rigid base together form a coil installation position with an open front side;

[0009] The rigid base is provided with at least one coil wire outlet through hole, and the coil wire passes vertically through the coil wire outlet through hole and is led out.

[0010] Furthermore, the magnetic core side column includes a first L-shaped magnetic core, a second L-shaped magnetic core, a first side column insulating spacer, and a second side column insulating spacer; the rear ends of the first L-shaped magnetic core and the second L-shaped magnetic core are attracted to each other, and the front ends of the first L-shaped magnetic core and the second L-shaped magnetic core are buckled to fix the magnetic circuit center column;

[0011] The first side column insulating spacer is arranged between the front of the first L-shaped magnetic core and the left side of the coil, and the second side column insulating spacer is arranged between the front of the second L-shaped magnetic core and the right side of the coil. There is a gap between the rear end portions of the first L-shaped magnetic core and the second L-shaped magnetic core and the back of the coil respectively.

[0012] Furthermore, the coil is wound with a flat wire, and the short end of the flat wire is wound along the center column of the magnetic circuit.

[0013] Furthermore, the center column of the magnetic circuit includes a center column insulating spacer, multiple air gap spacers and a center column magnetic core; the air gap spacers and the center column magnetic core are spaced and fitted together between the front of the first L-shaped magnetic core and the second L-shaped magnetic core to form a column, and the air gap spacers are fitted between the first L-shaped magnetic core and the center column magnetic core, as well as between the second L-shaped magnetic core and the center column magnetic core, and the center column insulating spacer is sleeved on the column, wrapping the contact surface between the column and the coil.

[0014] Furthermore, the thickness of the air gap spacer does not exceed 0.5 mm.

[0015] Furthermore, the center column magnetic core is made of ferrite material.

[0016] Furthermore, the rigid base is provided with at least one installation direction limiting structure.

[0017] Furthermore, the rigid base is provided with a coil limiting groove corresponding to the coil, and the bottom of the coil is limited in the coil limiting groove.

[0018] Furthermore, a first protruding structure is provided on the front right side of the first L-shaped magnetic core corresponding to the center column of the magnetic circuit, and a second protruding structure is provided on the front left side of the second L-shaped magnetic core corresponding to the center column of the magnetic circuit, and the first side column insulating spacer and the second side column insulating spacer are respectively arranged on the first protruding structure and the second protruding structure.

[0019] Furthermore, rear ends of the first side column insulating spacer and the second side column insulating spacer respectively abut against front ends of rear ends of the first L-shaped magnetic core and the second L-shaped magnetic core.

[0020] The technical solution provided by the present invention may include the following beneficial effects: the magnetic circuit center column is horizontally installed on the front of the magnetic core side column, so that the winding can be vertically wound around the magnetic circuit center column in accordance with gravity to form a coil, preventing the winding from being biased during the winding process, which is conducive to accommodating thicker wires, thereby adapting to high current and high voltage applications; then the magnetic core side column is vertically installed on the top surface of the rigid base, and the front of the magnetic core side column and the top surface of the rigid base are combined to form a coil setting position with an open front side. On the one hand, it is convenient for the exposed part of the coil to be concentrated on the front side for centralized heat dissipation; on the other hand, since the high current and high voltage inductor coil is relatively heavy, this design makes it easy to use the magnetic core side column and the rigid base to form an L-shaped coil support structure. When the inductor is set on the edge of the circuit board or the device, it can lean against the outer shell to improve the stability of the coil; more importantly, the single-sided magnetic core side column has a simple structure, the number of modified side columns is small, and it is easier to design inductors of different specifications. On this basis, the coil is wound vertically, and the outgoing wire can be led out through the coil outgoing wire hole of the rigid base, avoiding the risk of breakage caused by bending of large-diameter winding wires, especially when multi-channel inductor outgoing wires are required.

[0021] It should be noted that the base of the traditional filter inductor only serves as a structural component, mainly used to connect other components and for heat dissipation, insulation, etc., while in this embodiment, it is optimized into a rigid base, which increases the rigidity of the base and can provide sufficient support for the heavier magnetic circuit center column, coil and core side column. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a structural diagram of a novel filter inductor structure in one embodiment of the present utility model.

[0023] Figure 2 Yes Figure 1 The figure shows an assembly diagram of a new filter inductor structure.

[0024] Among them: the magnetic circuit center column 1, the coil 2, the rigid base 3, the magnetic core side column 4, the coil setting position 5, the first L-shaped magnetic core 41, the second L-shaped magnetic core 42, the first side column insulating spacer 43, the second side column insulating spacer 44, the air gap spacer 11, the center column magnetic core 12, the center column insulating spacer 13, the installation direction limiting structure 33, the coil limiting groove 32, the first protrusion structure 411, and the second protrusion structure 421. DETAILED DESCRIPTION

[0025] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0026] In the description of the present invention, it should be understood that the terms "longitudinal", "transverse", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction, and therefore should not be understood as limiting the present invention. In addition, features defined as "first" or "second" may explicitly or implicitly include one or more such features, and are used to distinguish between the described features, without distinction of order or importance.

[0027] In the description of the present invention, unless otherwise specified, “a plurality of” means two or more.

[0028] In the description of the embodiments of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to direct connections or indirect connections through an intermediate medium; they may refer to internal communication between two components or an interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the embodiments of the present invention based on specific circumstances.

[0029] The following combination Figures 1 to 2 , describing a new type of filtering inductor structure in an embodiment of the present utility model.

[0030] A novel filter inductor structure includes a magnetic circuit center column 1, a coil 2, a rigid base 3, and a magnetic core side column 4. The magnetic circuit center column 1 is horizontally mounted in front of the magnetic core side column 4, the coil 2 is wound around the magnetic circuit center column 1, and the magnetic core side column 4 is vertically mounted on the top surface of the rigid base 3. The front of the magnetic core side column 4 and the top surface of the rigid base 3 together form a coil setting position 5 with an open front side.

[0031] The rigid base 3 is provided with at least one coil wire outlet through-hole 31 , and the wire of the coil 2 passes vertically through the coil wire outlet through-hole 31 and is led out.

[0032] The present invention proposes a novel preferred embodiment of a filter inductor structure, such as Figure 1 As shown, the magnetic circuit center column 1 is installed horizontally on the front of the magnetic core side column 4, so that the winding can be vertically wound around the magnetic circuit center column 1 to form the coil 2 according to gravity, preventing the winding from being biased during the winding process, which is conducive to accommodating thicker wires, thereby adapting to high current and high voltage applications; then the magnetic core side column 4 is vertically installed on the top surface of the rigid base 3, and the front of the magnetic core side column 4 and the top surface of the rigid base 3 are enclosed to form a coil setting position 5 with an open front side. On the one hand, it is convenient for the exposed part of the coil 2 to be concentrated on the front side for centralized heat dissipation; on the other hand, since the inductor coil with high current and high voltage is relatively heavy, this design makes it easy to use the magnetic core side column 4 and the rigid base 3 to form an L-shaped coil support structure. When the inductor is set at the edge of the circuit board or the device, it can lean against the outer shell to improve the stability of the coil 2; more importantly, the single-sided magnetic core side column 4 has a simple structure, the number of modified side columns is small, and it is easier to design inductors of different specifications. On this basis, the coil 2 is wound vertically, and the outgoing wire can be led out from the coil outgoing wire through hole 31 of the rigid base 3, avoiding the risk of breakage caused by bending of large-diameter winding wire, especially when multi-channel inductor outgoing wires are required.

[0033] It should be noted that the base of the traditional filter inductor only serves as a structural component, mainly used to connect other components and for heat dissipation, insulation, etc., while in this embodiment it is optimized into a rigid base 3, which increases the rigidity of the base and can provide sufficient support for the heavier magnetic circuit center column 1, coil 2 and magnetic core side column 4.

[0034] Furthermore, the magnetic core side column 4 includes a first L-shaped magnetic core 41, a second L-shaped magnetic core 42, a first side column insulating spacer 43, and a second side column insulating spacer 44; the rear ends of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 are attracted to each other, and the front ends of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 are buckled to fix the magnetic circuit center column 1;

[0035] The first side column insulating spacer 43 is arranged between the front of the first L-shaped magnetic core 41 and the left side of the coil 2, and the second side column insulating spacer 44 is arranged between the front of the second L-shaped magnetic core 42 and the right side of the coil 2. There is a gap between the rear end portions of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 and the back of the coil 2 respectively.

[0036] In this embodiment, Figure 2 As shown, because the magnetic core side column 4 is to be placed horizontally in front of the magnetic circuit center column 1, it is preferably divided into two parts to facilitate the installation of the magnetic circuit center column 1. Therefore, the magnetic core side column 4 is composed of a first L-shaped magnetic core 41, a second L-shaped magnetic core 42, a first side column insulating spacer 43, and a second side column insulating spacer 44. The rear ends of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 are attracted to form a frame at their front ends, while forming a coil accommodating space between the front ends. After the front ends of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 are fastened to fix the magnetic circuit center column 1, the coil 2 can be wound smoothly.

[0037] More importantly, based on the insulation requirements of the inductor, the first side column insulating spacer 43 is set between the front of the first L-shaped magnetic core 41 and the left side of the coil 2, and the second side column insulating spacer 44 is set between the front of the second L-shaped magnetic core 42 and the right side of the coil 2, and there is a gap (air insulation) between the rear end portions of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 and the back of the coil 2, respectively, to constitute insulation between the magnetic core side column 4 and the coil 2.

[0038] Furthermore, the coil 2 is wound with a flat wire, and the short end of the flat wire is wound along the central column 1 of the magnetic circuit.

[0039] In this embodiment, the coil 2 is preferably wound with a flat wire (generally using materials such as copper or ferrite), and the short end of the flat wire is used to wind along the magnetic circuit column 1; this design can be compatible with windings of different diameters by moving the magnetic circuit column 1 to the front position of the magnetic core side column 4 when the inductance specification does not change much. For example, when the winding diameter needs to be increased, the long end of the flat wire is mainly extended, and the magnetic circuit column 1 is moved forward.

[0040] Furthermore, the center column 1 of the magnetic circuit includes a center column insulating sleeve 13, multiple air gap spacers 11 and a center column magnetic core 12; the air gap spacers 11 and the center column magnetic core 12 are spaced apart and bonded to each other between the front of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 to form a column, and air gap spacers 11 are bonded between the first L-shaped magnetic core 41 and the center column magnetic core 12 and between the second L-shaped magnetic core 42 and the center column magnetic core 12. The center column insulating sleeve 13 is sleeved on the column, wrapping the contact surface between the column and the coil 2.

[0041] In this embodiment, in order to reduce the magnetic resistance, the center column 1 of the magnetic circuit is composed of multiple air gap spacers 11 and a center column core 12 spaced apart and fitted together between the front parts of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 to form a column, thereby forming a closed magnetic circuit. This design allows the air gap to be evenly distributed, and the heat of the center column 1 of the magnetic circuit is not concentrated in one air gap position; and based on the insulation requirements of the inductor, the center column insulating spacer 13 (which can be made of winding insulating paper or a shaped insulating paper sleeve) is sleeved on the column to wrap the contact surface between the column and the coil 2, so that the center column 1 of the magnetic circuit and the coil 2 are insulated and separated.

[0042] Furthermore, the thickness of the air gap spacer 11 does not exceed 0.5 mm.

[0043] In this embodiment, because the size of the air gap of the column 1 in the magnetic circuit is determined by the thickness of the air gap spacer 11, and the function of the air gap is to reduce the magnetic permeability, reduce the dependence of the coil 2 on the initial magnetic permeability of the magnetic core material, and better control the inductance of the inductor to avoid magnetic saturation under large AC signals or DC bias, the thickness of the air gap spacer 11 is preferably not more than 0.5 mm to facilitate the regulation of the balance between magnetic permeability and inductance.

[0044] Furthermore, the middle column magnetic core 12 is made of ferrite material.

[0045] In this embodiment, the middle column magnetic core 12 is preferably made of ferrite material, which has advantages such as high magnetic permeability, high magnetic saturation, and relatively low cost compared to copper.

[0046] Furthermore, the rigid base 3 is provided with at least one installation direction limiting structure 33 .

[0047] In this embodiment, the inductor with high current and high voltage is relatively heavy. If it is installed incorrectly, it is difficult to correct it. Moreover, energizing the device after the installation error may cause serious consequences. Therefore, at least one installation direction limiting structure 33 should be provided on the rigid base 3. Only when the inductor is installed correctly can the limiting effect be achieved, so as to facilitate identification of the correct inductor installation direction. For example, Figure 2 As shown in the figure, an oblique notch (i.e., installation direction limiting structure 33) is provided in the rigid base 3, indicating that this direction is the front side of the inductor. A base limiting groove can also be provided on the bottom surface of the rigid base 3 at the installation position to cooperate with the limiting.

[0048] Furthermore, the rigid base 3 is provided with a coil limiting groove 32 corresponding to the coil 2 , and the bottom of the coil 2 is limited in the coil limiting groove 32 .

[0049] In this embodiment, because the magnetic core side column 4 is vertically installed on the top surface of the rigid base 3, it is only limited by the output wire of the coil 2 passing vertically through the coil output wire through-hole 31, and the magnetic core side column 4 is easy to deviate. Therefore, a coil limiting groove 32 is added to the rigid base 3 to limit the bottom of the coil 2, thereby enhancing the limiting and supporting effect of the magnetic core side column 4 and the coil 2.

[0050] Furthermore, a first protruding structure 411 is provided on the front right side of the first L-shaped magnetic core 41 corresponding to the center column 1 of the magnetic circuit, and a second protruding structure 421 is provided on the front left side of the second L-shaped magnetic core 42 corresponding to the center column 1 of the magnetic circuit, and the first side column insulating spacer 43 and the second side column insulating spacer 44 are respectively arranged on the first protruding structure 411 and the second protruding structure 421.

[0051] In this embodiment, in order to prevent the first side column insulating spacer 43 and the second side column insulating spacer 44 from shifting, a first protruding structure 411 and a second protruding structure 421 are respectively provided on the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 .

[0052] Furthermore, the rear ends of the first side column insulating spacer 43 and the second side column insulating spacer 44 respectively abut against the front ends of the rear ends of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 .

[0053] In this embodiment, in order to further prevent the first side column insulating spacer 43 and the second side column insulating spacer 44 from shifting, the rear ends of the first side column insulating spacer 43 and the second side column insulating spacer 44 are also abutted against the front of the rear ends of the first L-shaped magnetic core 41 and the second L-shaped magnetic core 42 respectively.

[0054] Other structures and operations of the novel filter inductor structure according to the embodiment of the present invention are known to those skilled in the art and will not be described in detail here.

[0055] Throughout this specification, references to terms such as "embodiment" and "example" indicate that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0056] Although the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and purpose of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A new filter inductor structure, characterized by: The magnetic circuit center column comprises a magnetic circuit center column, a coil, a rigid base, and a magnetic core side column; the magnetic circuit center column is horizontally mounted on the front of the magnetic core side column, the coil is wound on the magnetic circuit center column, and the magnetic core side column is vertically mounted on the top surface of the rigid base. The front of the magnetic core side column and the top surface of the rigid base together form a coil setting position with an open front side. The rigid base is provided with at least one coil wire outlet through hole, and the coil wire passes vertically through the coil wire outlet through hole and is led out.

2. The novel filter inductor structure according to claim 1, characterized in that: The magnetic core side column includes a first L-shaped magnetic core, a second L-shaped magnetic core, a first side column insulating spacer, and a second side column insulating spacer; the rear ends of the first L-shaped magnetic core and the second L-shaped magnetic core are attracted to each other, and the front ends of the first L-shaped magnetic core and the second L-shaped magnetic core are buckled to fix the magnetic circuit center column; The first side column insulating spacer is arranged between the front of the first L-shaped magnetic core and the left side of the coil, and the second side column insulating spacer is arranged between the front of the second L-shaped magnetic core and the right side of the coil. There is a gap between the rear end portions of the first L-shaped magnetic core and the second L-shaped magnetic core and the back of the coil respectively.

3. The novel filter inductor structure according to claim 1, characterized in that: The coil is wound with a flat wire, and the short end of the flat wire is wound along the center column of the magnetic circuit.

4. The novel filter inductor structure according to claim 2, characterized in that: The center column of the magnetic circuit includes a center column insulating spacer, multiple air gap spacers and a center column magnetic core; the air gap spacers and the center column magnetic core are spaced and bonded to each other between the front of the first L-shaped magnetic core and the second L-shaped magnetic core to form a column, and the air gap spacers are bonded between the first L-shaped magnetic core and the center column magnetic core, as well as between the second L-shaped magnetic core and the center column magnetic core. The center column insulating spacer is sleeved on the column, wrapping the contact surface between the column and the coil.

5. The novel filter inductor structure according to claim 4, characterized in that: The thickness of the air gap spacer does not exceed 0.5 mm.

6. The novel filter inductor structure according to claim 4, characterized in that: The middle column magnetic core is made of ferrite material.

7. The novel filter inductor structure according to claim 1, characterized in that: The rigid base is provided with at least one installation direction limiting structure.

8. The novel filter inductor structure according to claim 1, characterized in that: The rigid base is provided with a coil limiting groove corresponding to the coil, and the bottom of the coil is limited in the coil limiting groove.

9. The novel filter inductor structure according to claim 2, characterized in that: A first protruding structure is provided on the right front side of the first L-shaped magnetic core corresponding to the center column of the magnetic circuit, and a second protruding structure is provided on the left front side of the second L-shaped magnetic core corresponding to the center column of the magnetic circuit. The first side column insulating spacer and the second side column insulating spacer are respectively arranged on the first protruding structure and the second protruding structure.

10. The novel filter inductor structure according to claim 2, characterized in that: The rear ends of the first side column insulating spacer and the second side column insulating spacer respectively abut against the front ends of the rear ends of the first L-shaped magnetic core and the second L-shaped magnetic core.

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