High-voltage high-power magnetic device and inverter equipment

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By optimizing the skeleton structure and potting process, the problems of large volume and heavy weight of high-voltage and high-power magnetic devices were solved, the size of the magnetic devices was reduced and the power density was increased, ensuring the safety and stability of the devices.

CN223450667UActive Publication Date: 2025-10-17SHANGHAI SIGEYUAN INTELLIGENT TECH CO LTD

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Patent Information

Application Number: CN202422912729.8
Authority / Receiving Office: CN · China
Patent Type: Utility models(China)
Current Assignee / Owner
Filing Date: 2024-11-27
Publication Date: 2025-10-17
Estimated Expiration: 2034-11-27

AI Technical Summary

Technical Problem

Existing high-voltage and high-power magnetic devices are large in size, heavy in weight, and high in cost, making it difficult to increase the power density without changing the core and coil design.

Method used

A new skeleton structure is designed, including oblique supports and limit pads. By optimizing the potting process, sufficient filling of the potting compound is ensured, the creepage distance and electrical clearance between the magnetic components and the casing are reduced, and smaller limit pads are used to meet safety requirements.

Benefits of technology

Without changing the core and coil design, the overall size of the magnetic device is effectively reduced, the power density is improved, and the stable operation and reliability of the device are guaranteed through thermal conductive potting glue.

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Abstract

The utility model discloses a high-voltage and high-power magnetic device and inverter equipment. The high-voltage and high-power magnetic device comprises a metal shell and a magnetic part arranged in the shell, and further comprises a framework, a limiting pad and pouring sealant, wherein the framework is arranged in the shell, the framework is used for supporting the magnetic component, and inclined supporting columns which extend to the shell and are in contact with the shell are arranged on the periphery of the framework; the limiting pad is arranged on the framework, the limiting pad is used for fixing the magnetic component, and a distance is reserved between the limiting pad and the shell; and the pouring sealant is filled in the shell so as to form solid insulation. According to the high-voltage and high-power magnetic device, the design of the magnetic core and the coil is not changed, the framework structure is optimized, so that the large creepage distance can be ensured, meanwhile, the overall size of the magnetic component is slightly increased, and the high-voltage and high-power magnetic device has high power density.

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Description

TECHNICAL FIELD

[0001] The utility model relates to magnetic device technical field especially relates to a high voltage high -power magnetic device and inverter equipment. BACKGROUND

[0002] With the rapid development of global electronic industry, the demand of various electronic products is increasing, and in the electronic products, magnetic devices are very common. The power of existing electronic products is increasing, and the voltage is also increasing. For example, in various products such as photovoltaic inverters, charging piles, etc., the power is higher than 100KW, and the voltage is higher than 800V. The magnetic device in high-power occasions has large power consumption. In addition, due to the safety requirements, the electrical clearance and creepage distance corresponding to high voltage are large, so the volume of the magnetic device is also large, which leads to the increase of the volume of the electronic product, and further brings the weight and cost disadvantage. Therefore, how to improve the power density of high voltage high power magnetic device is an eternal issue.

[0003] At present, there are mainly two measures to reduce the volume of high-power magnetic devices: 1. From the electrical aspect, such as increasing the working frequency, but this needs to be considered comprehensively from the overall electrical aspect. 2. From the process design of magnetic device, adopt the glue filling method, so that it can withstand more power consumption with smaller volume, which is helpful to reduce the volume. Generally, the glue filling shell is metal and its potential is reference ground, so there is a large safety distance requirement between the electrical part of the magnetic device (i.e. coil and magnetic core) and the metal shell, but through solid insulation experiment verification method, the distance between the coil and the magnetic core and the metal shell can be reduced.

[0004] Referring to the drawings Figure 5 It shows a common structure of a magnetic device, from the figure, it can be seen that the framework is provided with a plurality of limiting pads, which are used to fix the magnetic parts (i.e. coil and magnetic core) on one hand, and to limit the position of the framework in the shell on the other hand, to prevent it from moving. Usually, the limiting pad is clamped between the shell and the coil and the magnetic core, so that the framework is fixed in the shell and cannot shake, but due to the glue filling process, the glue filling at the limiting pad of the framework is not complete, and bubbles cannot be avoided, so the size of the limiting pad is the distance between the metal shell and the coil or the magnetic core, and because of the bubbles, the safety distance at this place cannot be referred to solid insulation, but must be referred to no glue filling insulation. If the safety distance requirement is small, the size of the limiting pad is also small, which has limited effect on the increase of the total size, but for larger systems, such as photovoltaic inverter occasions, especially high voltage occasions, the safety distance requirement is large, such as the electrical clearance is generally higher than 10mm, and the creepage distance is higher than 20mm. In such occasions, a larger size limiting pad is required, and the magnetic parts must be at the same distance around the magnetic parts, so that the whole magnetic parts (including the magnetic parts and the shell) increase a larger space than the magnetic parts. UTILITY MODEL CONTENTS

[0005] The utility model discloses a high -voltage high -power magnetic device and inverter equipment, on the basis of not changing the magnetic core and coil design, through design a novel framework, even if the safety regulation distance requirement is larger, still can adopt smaller size limit pad, make the whole volume of magnetic piece only increase smaller space compared with the magnetic piece body, further reduce the whole size of magnetic piece, and improve its power density.

[0006] The utility model discloses the purpose realizes by adopting the following technical scheme:

[0007] A high -voltage high -power magnetic device, including the shell of metal and the magnetic component of setting in the shell, still include:

[0008] Framework, set up in the shell, the framework is used to support the magnetic component, and its four all are equipped with the inclined support extending to the shell and with contact therefrom;

[0009] Limit pad, set up on the framework, the limit pad is used for fixing the magnetic component, and the distance is left between with the shell;

[0010] Potting adhesive, fill in the shell and form solid insulation by this.

[0011] In some embodiments, the creepage distance L of the magnetic component to the shell is not less than 20mm.

[0012] In some embodiments, the distance of the limit pad to the shell is greater than 1mm.

[0013] In some embodiments, the distance of the limit pad to the shell is less than 1.5mm.

[0014] In some embodiments, the potting adhesive is heat-conducting potting adhesive.

[0015] In some embodiments, the magnetic component includes the magnetic core of upper and lower interval arrangement and the coil of left and right side by side arrangement between the magnetic core.

[0016] In some embodiments, the number of the coil of left and right side by side arrangement is at least one group.

[0017] In some embodiments, the magnetic component includes the magnetic core of left and right interval arrangement and the coil of upper and lower parallel arrangement between the magnetic core.

[0018] In some embodiments, the number of the coil of upper and lower parallel arrangement is at least one group.

[0019] An inverter device includes the high -voltage high -power magnetic device of any one of the above.

[0020] Compared with the prior art, the high-pressure high-power magnetic device has the advantages of not changing the design of the magnetic core and the coil, optimizing the framework structure to ensure a large creepage distance, and only slightly increasing the overall size of the magnetic component while having a high power density. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is a structural schematic diagram of a high-pressure high-power magnetic device of embodiment 1.

[0022] Figure 2 is a structural schematic diagram of a high-pressure high-power magnetic device of embodiment 2.

[0023] Figure 3 is a structural schematic diagram of a high-pressure high-power magnetic device of embodiment 3.

[0024] Figure 4 is a structural schematic diagram of a high-pressure high-power magnetic device of embodiment 4.

[0025] Figure 5 is a structural schematic diagram of a magnetic device in the prior art.

[0026] In the figure: 1, shell; 2, magnetic component; 21, magnetic core; 22, coil; 3, framework; 4, inclined support column; 5, limiting pad; 6, potting glue. DETAILED DESCRIPTION

[0027] Example implementations will now be described more fully with reference to the accompanying drawings. Example implementations may, however, be implemented in many different forms and should not be construed as limited to the implementations set forth herein; rather, these implementations are provided so that this disclosure will be thorough and complete, and fully convey the inventive aspects of example implementations to those skilled in the art. Like reference numerals refer to like elements throughout the figures, and descriptions of the same elements will not be repeated.

[0028] The words expressing position and direction described in the present application are illustrated by taking the drawings as an example, but changes can also be made according to needs, and the changes made are all included in the protection scope of the present application.

[0029] Referring to Figures 1 to 4 As shown in the figure, the utility model discloses a kind of high-pressure high-power magnetic devices, its working voltage exceeds 800V, power is higher than 100KW.The magnetic device includes shell 1 and magnetic component 2, it also includes framework 3, inclined support column 4, limiting pad 5 and potting glue 6.

[0030] The shell 1 is made of metal, for example, an aluminum shell in a rectangular shape. The magnetic component 2 is arranged in the shell 1 and includes a magnetic core 21 and a coil 22, which are well known to those skilled in the art. The arrangement of the magnetic component 2 in the shell 1 is also well known to those skilled in the art and is described in detail in Examples 1 to 4.

[0031] The skeleton 3 is also arranged in the shell 1 and is used to support the magnetic component 2. The magnetic component 2 can be fixed around its periphery by a limiting pad 5 arranged on the skeleton 3 so that the magnetic component 2 is mounted on the skeleton 3. In this application, the limiting pad 5 only fixes the position of the magnetic component 2 (the magnetic core 21 and the coil 22) and does not participate in the fixation of the position of the skeleton 3. The limiting pad 5 is spaced apart from the shell 1 by a certain distance (for example, 1 mm), which can ensure the glue pouring process so that the potting glue 6 completely fills between the magnetic component 2 and the shell 1. Because the glue pouring process is perfect, the magnetic component 2 is covered by the potting glue 6 between the shell 1, so the magnetic component 2 can be solidly insulated between the shell 1. Even if the safety requirements are high (for example, the electrical clearance needs to be 10 mm and the creepage distance needs to be 20 mm), the distance between the magnetic component 2 and the shell 1 can be greatly reduced (for example, only 3 mm can meet the safety requirements).

[0032] In addition, the skeleton 3 is provided with a diagonal support 4 extending to the shell 1 and contacting the shell 1, which contacts the shell 1 and fixes the skeleton 3 to avoid the magnetic component 2 from shaking. Also limited by the current glue pouring process, there may be air bubbles at the contact between the diagonal support 4 and the shell 1, so the electrical spacing and the creepage distance of the magnetic component 2 and the shell 1 at the diagonal support 4 are higher. However, in this application, because the glue pouring between the magnetic component 2 and the shell 1 is good, the main consideration is the creepage distance. From Figure 1 It can be seen that the diagonal support 4 is in close contact with the shell 1, and the gap between them is too short. There may be air bubbles at the contact between the diagonal support 4 and the shell 1 (point A in the middle). Figure 1 Therefore, the creepage distance at this time should be calculated under air conditions, not under glue pouring conditions.

[0033] Referring to Figure 1 , the creepage distance L of the magnetic component 2 and the shell 1 is calculated as follows:

[0034] L = AB + BC + CD + DE

[0035] AB is the distance between A and B, and BC, CD, DE are the distances between B and C, C and D, and D and E respectively. Since AB is the diagonal pillar 4, the length of the diagonal pillar 4 can be designed to be larger, and in addition, the distance between BC, CD, and DE, even if the creepage distance required by the safety regulations is large (for example, the creepage distance needs to be 20 mm), L is also easier to meet this requirement. Similarly, for the diagonal pillars 4 in other directions (such as the upper left corner, the lower left corner, and the lower right corner), their creepage distances can also be calculated similarly, and it is also easier to meet the larger creepage distance required by the safety regulations. In this way, by optimizing the structure of the skeleton 3, the distance between the magnetic component 2 and the shell 1 can be effectively shortened, and the overall size of the magnetic component 2 (magnetic component 2 + shell 1) only extends a small distance outward on the basis of the magnetic component 2 (for example, the original magnetic component 2 needs to extend 20 mm in all directions, but after using the structure of the skeleton 3, the original magnetic component 2 needs to extend 3 mm in all directions), which makes the overall volume of the magnetic component 2 increase less, and the magnetic device has a higher power density.

[0036] In summary, the high-voltage high-power magnetic device of the present application does not change the magnetic component 2, but by designing a new type of skeleton 3, even if the safety distance requirement is large, a smaller size limiting pad 5 can be used, so that the overall volume of the magnetic component increases only a small space compared to the magnetic component body, further reducing the overall size of the magnetic component and improving its power density.

[0037] In some embodiments, the creepage distance L of the magnetic component 2 to the shell 1 is not less than 20 mm, so as to ensure the safety and reliability of the high-voltage high-power magnetic device and prevent accidents such as electric shock and short circuit.

[0038] In some embodiments, the distance between the limiting pad 5 and the shell 1 is greater than 1 mm, and / or the distance between the limiting pad 5 and the shell 1 is less than 1.5 mm. By reserving a certain distance, the gap between the limiting pad 5 and the shell 1 can be fully filled with glue, and because the glue is completely filled, the magnetic component 2 and the shell 1 can be fixed and insulated, thereby greatly reducing the volume of the magnetic device. In the present application, the distance between the limiting pad 5 and the shell 1 can be 1 mm-1.5 mm, preferably 1 mm.

[0039] In some embodiments, the skeleton 3 is integrally formed with the diagonal pillar 4 and the limiting pad 5.

[0040] In some embodiments, the potting glue 6 is a heat-conducting potting glue 6, which can effectively conduct the heat generated by the magnetic component 2 out while forming a solid insulation, preventing overheating problems, ensuring stable operation of the high-voltage high-power magnetic device, and improving its durability and reliability.

[0041] Embodiment 1

[0042] Example 1 discloses a configuration method of the magnetic component 2 in the housing 1 of the present application. Figure 1 As shown, the magnetic component 2 includes magnetic cores 21 spaced apart from each other and coils 22 arranged side by side between the magnetic cores 21 .

[0043] Example 2

[0044] See also Figure 2 As shown, Example 2 also discloses a configuration of the magnetic component 2, which is based on Example 1, except that the coils 22 arranged side by side on the left and right are grouped in pairs, totaling two groups, and are all located between the magnetic cores 21. In the magnetic component 2 of this embodiment, the four coils 22 can be two inductors or a set of primary and secondary coils 22 of a transformer.

[0045] It should be noted that the number of groups is not limited and can also be three, four or more groups.

[0046] Example 3

[0047] Example 3 discloses another arrangement of the magnetic component 2 in the housing 1 of the present application. Figure 3 As shown, the magnetic component 2 includes magnetic cores 21 spaced apart from each other on the left and right sides and coils 22 arranged vertically and parallelly between the magnetic cores 21 .

[0048] Example 4

[0049] See also Figure 4 As shown, the difference between Example 4 and Example 3 is that the coils 22 arranged in parallel up and down are in two groups, and are all located between the magnetic cores 21.

[0050] The present utility model also discloses an inverter device, such as a photovoltaic inverter device, which includes any of the above-mentioned high-voltage and high-power magnetic devices, which can effectively reduce the volume, have a higher power density, and improve advantages in weight and cost.

[0051] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are illustrative and cannot be understood as limiting the present invention. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the utility model without departing from the principles and purpose of the utility model. All of these changes should fall within the scope of protection of the claims of the present invention.

Claims

1. A high-voltage, high-power magnetic device, comprising a metal housing (1) and a magnetic component (2) disposed within the housing (1), characterized in that: Also includes: A skeleton (3) is arranged in the housing (1), the skeleton (3) is used to support the magnetic component (2), and is provided with oblique supports (4) extending to and in contact with the housing (1) on all sides thereof; A limiting pad (5) is provided on the frame (3), the limiting pad (5) is used to fix the magnetic component (2), and a distance is left between the limiting pad (5) and the housing (1); A potting compound (6) is filled in the housing (1) to form solid insulation.

2. The high-voltage and high-power magnetic device according to claim 1, characterized in that: The creepage distance L between the magnetic component (2) and the housing (1) is not less than 20 mm.

3. The high-voltage and high-power magnetic device according to claim 1, characterized in that: The distance between the limiting pad (5) and the housing (1) is greater than 1 mm.

4. The high-voltage and high-power magnetic device according to claim 1, characterized in that: The distance between the limiting pad (5) and the housing (1) is less than 1.5 mm.

5. The high-voltage and high-power magnetic device according to claim 1, characterized in that: The potting glue (6) is a heat-conducting potting glue.

6. The high-voltage and high-power magnetic device according to claim 1, characterized in that: The magnetic component (2) comprises magnetic cores (21) spaced apart from each other and coils (22) arranged side by side between the magnetic cores (21).

7. The high-voltage and high-power magnetic device according to claim 6, characterized in that: The number of the coils (22) arranged side by side on the left and right is at least one group.

8. The high-voltage and high-power magnetic device according to claim 1, characterized in that: The magnetic component (2) comprises magnetic cores (21) arranged at intervals on the left and right, and coils (22) arranged vertically and parallelly between the magnetic cores (21).

9. The high-voltage and high-power magnetic device according to claim 8, characterized in that: The number of the coils (22) arranged in parallel up and down is at least one group.

10. An inverter device, characterized in that: The invention comprises a high-voltage and high-power magnetic device as described in any one of claims 1 to 9.