Differential mode and common mode integrated inductor

Abstract

The utility model discloses a differential mode and common mode integrated inductor which comprises a magnetic core, a copper bar group and an insulating material. Wherein the magnetic core at least comprises two winding areas and magnetic conductive pieces located between the two adjacent winding areas, the copper bar sets are arranged in the winding areas and comprise multiple circles of copper bars wound around the winding areas, and the winding directions of the copper bars of the at least two copper bar sets are opposite; and the insulating material is arranged between the magnetic core and the copper bar groups and between the adjacent copper bars in any copper bar group. The differential-mode and common-mode integrated inductor provided by the utility model has the functions of a common-mode inductor and a differential-mode inductor at the same time, so that the differential-mode inductor and the common-mode inductor are integrated on the same magnetic core, the number of filter inductors can be reduced, the efficiency of a circuit can be improved, and the suppression effect on the electromagnetic compatibility of an automobile electric drive can be enhanced.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and more specifically, to a differential and common-mode integrated inductor. Background Technology

[0002] Electromagnetic compatibility (EMC) in automotive electric drives refers to the electromagnetic interference and compatibility issues that may occur between the electronic systems of electric vehicles and their surrounding environment. Current methods for addressing EMC issues in automotive electric drives include... Figure 1 As shown in the figure, this is a common-mode inductor structure, including a magnetic core 01, a copper busbar injection-molded housing 02, and a copper busbar 03. The copper busbar 03 passes directly through the magnetic core 01. The copper busbar injection-molded housing 02 is set between the magnetic core 01 and the copper busbar 03. The copper busbar injection-molded housing 02 achieves insulation between the magnetic core 01 and the copper busbar 03 through injection molding. This method can only suppress common-mode interference, and the copper busbar 03 has a small number of winding turns, resulting in poor suppression effect.

[0003] Therefore, how to design a differential and common-mode integrated inductor to enhance the electromagnetic compatibility suppression effect of automotive electric drives has become a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0004] In view of this, the purpose of this utility model is to provide a differential and common-mode integrated inductor to enhance the electromagnetic compatibility suppression effect of automotive electric drives.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A differential and common-mode integrated inductor, comprising:

[0007] A magnetic core, comprising at least two winding regions and a magnetic conductor located between two adjacent winding regions;

[0008] A copper busbar group is provided in the winding area. The copper busbar group includes multiple turns of copper busbars wound in the winding area, and the copper busbars of at least two copper busbar groups have opposite winding directions.

[0009] Insulating material is provided between the magnetic core and the copper busbar assembly, as well as between adjacent copper busbars in any copper busbar assembly.

[0010] Optionally, in the above-mentioned differential and common-mode integrated inductor, the number of turns of the copper busbars in each copper busbar group is N+1 / 2 turns.

[0011] Optionally, in the aforementioned differential and common-mode integrated inductor, the copper busbar group includes multiple copper busbars connected in sequence, with each copper busbar being wound concentrically around the circumferential winding area.

[0012] Optionally, in the above-mentioned differential and common-mode integrated inductor, adjacent copper busbars are connected by welding.

[0013] Optionally, in the above-mentioned differential and common mode integrated inductor, the winding region includes a first winding region and a second winding region, and the copper busbar group includes a first copper busbar group and a second copper busbar group, and the insulating material includes a first insulating material and a second insulating material.

[0014] The first copper busbar group is located in the first winding area, and the second copper busbar group is located in the second winding area. The first copper busbar group and the second copper busbar group are arranged symmetrically. The first insulating material is located in the first winding area, and the second insulating material is located in the second winding area.

[0015] Optionally, in the above-mentioned differential and common-mode integrated inductor, the magnetic core includes a first magnetic core and a second magnetic core, with the first magnetic core and the second magnetic core arranged opposite to each other.

[0016] Optionally, in the above-mentioned differential and common-mode integrated inductor, the left magnetic post of the first magnetic core abuts against the left magnetic post of the second magnetic core to form a first winding region, the right magnetic post of the first magnetic core abuts against the right magnetic post of the second magnetic core to form a second winding region, and the center magnetic post of the first magnetic core abuts against the center magnetic post of the second magnetic core to form a magnetic conductor.

[0017] Optionally, in the above-mentioned differential and common-mode integrated inductor, the outlines of the first magnetic core and the second magnetic core are both rectangular, and the shapes of the central magnetic post of the first magnetic core and the central magnetic post of the second magnetic core include rectangular and cylindrical shapes.

[0018] Optionally, in the above-mentioned differential and common-mode integrated inductor, the insulating material is insulating paper.

[0019] Optionally, in the above-mentioned differential and common mode integrated inductor, both ends of the copper busbar are provided with connection through holes.

[0020] This invention provides an integrated differential and common-mode inductor with multiple turns of the copper busbar, which enhances the suppression of electromagnetic compatibility (EMC) in automotive electric drives by increasing the inductance. At least two copper busbars have coils wound in opposite directions, thus functioning as a common-mode inductor. A magnetic conductor is placed between adjacent winding areas, generating magnetic induction with the copper busbars wound in adjacent areas, thereby functioning as a differential-mode inductor. This integrated differential and common-mode inductor integrates differential and common-mode inductors onto the same magnetic core, reducing the number of filter inductors, improving circuit efficiency, and enhancing the suppression of EMC in automotive electric drives. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 A schematic diagram of a common-mode inductor in the prior art;

[0023] Figure 2 This is a schematic diagram of the differential and common-mode integrated inductor disclosed in an embodiment of the present invention;

[0024] Figure 3 This is a schematic diagram of the copper busbar structure of the differential and common mode integrated inductor disclosed in an embodiment of this utility model;

[0025] Figure 4 This is a schematic diagram of the insulating material of the differential and common mode integrated inductor disclosed in an embodiment of this utility model;

[0026] Figure 5 This is a schematic diagram of the magnetic core structure of the differential and common-mode integrated inductor disclosed in an embodiment of this utility model.

[0027] Among them, 01 is the magnetic core, 02 is the copper busbar injection molded shell, and 03 is the copper busbar;

[0028] 10. Magnetic core; 11. First magnetic core; 12. Second magnetic core;

[0029] 20. Bronze busbar group; 21. First bronze busbar group; 22. Second bronze busbar group;

[0030] 30. Insulating material; 31. First insulating material; 32. Second insulating material. Detailed Implementation

[0031] In addition to the problems mentioned in the background technology, the existing technology uses a copper busbar injection molded shell 03 to achieve insulation between the magnetic core 01 and the copper busbar 03, which also has the problem of occupying a large space.

[0032] The core of this invention lies in disclosing a differential and common-mode integrated inductor to enhance the electromagnetic compatibility suppression effect of automotive electric drives.

[0033] Hereinafter, embodiments will be described with reference to the accompanying drawings. Furthermore, the embodiments shown below do not limit the scope of the utility model as described in the claims. Additionally, the complete contents of the structures represented in the embodiments below are not limited to those necessary for the solution of the utility model as described in the claims. It should be noted that, for ease of description, only the parts relevant to the utility model are shown in the drawings. Unless otherwise specified, the embodiments and features in the embodiments of this utility model can be combined with each other.

[0034] To distinguish between existing technologies and the differential / common mode integrated inductors disclosed in this utility model, the same structure is marked differently.

[0035] like Figure 2As shown in the figure, this utility model embodiment discloses a differential and common mode integrated inductor, including a magnetic core 10, a copper busbar group 20 and an insulating material 30.

[0036] The magnetic core 10 includes at least two winding regions. Copper busbar groups 20 are disposed within these winding regions, each consisting of multiple turns of copper busbar wound around the winding region. One turn of the copper busbar is defined as one circumferential winding of the busbar around the winding region. Each copper busbar group 20 has at least one and a half turns of winding. Insulating material 30 is disposed between the magnetic core 10 and the copper busbar groups 20, as well as between adjacent copper busbars within any copper busbar group 20. The copper busbars in at least two of the copper busbar groups 20 are wound in opposite directions; that is, the copper busbars in one copper busbar group 20 are wound clockwise, while those in the other are wound counterclockwise, thus providing common-mode inductance (suppressing common-mode electromagnetic interference). Magnetic conductive elements are disposed between adjacent winding regions. These elements generate magnetic induction with the copper busbar groups 20 wound around the adjacent winding regions, thus providing differential-mode inductance (suppressing differential-mode interference).

[0037] It should be noted that the magnetic conductor is made of a magnetic material, which can be ferrite, nickel-iron alloy, or other ferromagnetic materials. The magnetic core 10 can be a one-piece structure with a cavity in which the magnetic conductor is housed; or the magnetic core 10 can be composed of multiple separate magnetic cores 10, and the specific method is not limited. The magnetic core 10 is made of a soft magnetic material with high permeability.

[0038] The differential and common-mode integrated inductor disclosed in this embodiment of the utility model has the functions of both common-mode and differential-mode inductors. By integrating the differential and common-mode inductors on the same magnetic core 10, the number of filter inductors can be reduced, the efficiency of the circuit can be improved, and the suppression effect on electromagnetic compatibility of automotive electric drives is better than that of the prior art which uses common-mode inductors.

[0039] According to the inductance calculation formula: L = AL × N², where L is the inductance value, AL is the inductance coefficient (usually given by the manufacturer), and N is the number of coil turns. Assuming AL is 5μH, when the number of coil turns is one, the inductance L = 5μH; when the number of coil turns is two, L = 5μH × 4 = 20μH. It can be seen that the more coil turns there are, the larger the inductance, and the better the electromagnetic compatibility suppression effect on automotive electric drives. The differential and common-mode integrated inductor disclosed in this embodiment of the invention uses a multi-turn copper busbar winding method, which increases the inductance and thus enhances the electromagnetic compatibility suppression effect on automotive electric drives. In summary, the differential and common-mode integrated inductor disclosed in this embodiment of the invention enhances the electromagnetic compatibility suppression effect on automotive electric drives.

[0040] The differential and common-mode integrated inductor disclosed in this embodiment of the invention has a copper busbar group 20 with N+1 / 2 turns, where N is a positive integer. This method ensures that the first and second ends of the copper busbar group 20 are exposed to the magnetic core 10, facilitating connection with other circuits.

[0041] The differential and common-mode integrated inductor disclosed in this embodiment of the invention comprises a copper busbar group 20 including multiple copper busbars connected in sequence, each copper busbar being concentrically wound around the circumferential winding area (circumferential winding). Specifically, the copper busbar group 20 is formed by bending and connecting the individual copper busbars. Figure 2 and Figure 3 As shown in the diagram, the copper busbar has one and a half turns. Specifically, it consists of two copper busbars. The first busbar is bent and wound around the circumference of the winding area once. The second busbar is bent and wound around the circumference of the winding area half a turn. The second busbar is located outside the first busbar, with the direction closer to the winding area considered the inside and the direction farther from the winding area considered the outside. The first end of the second busbar is connected to the second end of the first busbar, forming multiple turns of the copper busbar. The diagram is only an example; the first turn of the copper busbar located inside can also be formed by connecting two bent copper busbars.

[0042] Adjacent copper busbars can be connected by welding, with laser welding being the preferred method.

[0043] like Figures 2-4 As shown, in a specific embodiment of this utility model, the winding area includes a first winding area and a second winding area. The magnetic core 10 includes two cavities, and the cavities and the ends of the magnetic core 10 form the winding area. The copper busbar group 20 includes a first copper busbar group 21 and a second copper busbar group 22. The insulating material 30 includes a first insulating material 31 and a second insulating material 32. The first copper busbar group 21 is disposed in the first winding area, and the second copper busbar group 22 is disposed in the second winding area. The first copper busbar group 21 and the second copper busbar group 22 are symmetrically arranged, that is, the number of turns of the copper busbars in the first copper busbar group 21 and the second copper busbar group 22 are the same, and the winding directions are opposite. The first insulating material 31 is disposed in the first winding area, located between the first copper busbar group 21 and the magnetic core 10 and between adjacent copper busbars. The second insulating material 32 is disposed in the second winding area, located between the second copper busbar group 22 and the magnetic core 10 and between adjacent copper busbars.

[0044] like Figure 5 As shown, in a specific embodiment of this utility model, the magnetic core 10 includes a first magnetic core 11 and a second magnetic core 12, which are arranged opposite to each other to form a first winding region and a second winding region. It should be noted that the first magnetic core 11 and the second magnetic core 12 can be of the same or different types. For example, the first magnetic core 11 can be an E-type magnetic core, and the second magnetic core 12 can be an E-type magnetic core or an I-type magnetic core.

[0045] like Figure 3 and Figure 5As shown in a specific embodiment of this utility model, both the first magnetic core 11 and the second magnetic core 12 are EE-type magnetic cores. Specifically, the left magnetic post of the first magnetic core 11 abuts against the left magnetic post of the second magnetic core 12 to form a first winding region, and the right magnetic post of the first magnetic core 11 abuts against the right magnetic post of the second magnetic core to form a second winding region. The central magnetic post of the first magnetic core 11 and the central magnetic post of the second magnetic core 12 abut against each other to form a magnetic conductor. To increase the common-mode inductance value, the end faces of the first magnetic core 11 and the second magnetic core 12 that abut against each other can be mirror-finished.

[0046] To reduce magnetic reluctance and increase magnetic induction intensity, an air gap can be left between the central magnetic post of the first magnetic core 11 and the central magnetic post of the second magnetic core 12. Specifically, this can be achieved during processing by cutting off a portion of the central magnetic post of the first magnetic core 11 or the central magnetic post of the second magnetic core 12 using equipment such as a grinding machine. The magnitude of the differential mode inductance can be controlled by adjusting the length of the cut-off portion.

[0047] In a specific embodiment of this utility model, the outlines of the first magnetic core 11 and the second magnetic core 12 are both rectangular, and the shapes of the central magnetic post of the first magnetic core 11 and the central magnetic post of the second magnetic core 12 include rectangular and cylindrical shapes.

[0048] like Figures 2-4 As shown, in a specific embodiment of this utility model, the first magnetic core 11 and the second magnetic core 12 are arranged symmetrically, and the first insulating material 31 and the second insulating material 32 are arranged symmetrically.

[0049] The differential and common mode integrated inductor disclosed in this embodiment uses insulating paper as the insulating material. Compared with the copper busbar injection molded shell in the prior art, the insulating paper occupies less space, which can reduce the volume of the differential and common mode integrated inductor. Under the premise of ensuring insulation, the volume of the differential and common mode integrated inductor is minimized, making reasonable use of space.

[0050] To facilitate circuit connection, the differential and common mode integrated inductor disclosed in this embodiment of the invention has connection through holes at both ends of the copper busbar group 20.

[0051] In the description of the embodiments of this utility model, it should be noted that the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "connected" and "linked" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this utility model based on the specific circumstances.

[0052] This article uses specific examples to illustrate the principles and implementation methods of this utility model. The descriptions of the above embodiments are only for the purpose of helping to understand the core ideas of this utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made to this utility model without departing from the principles of this utility model, and these improvements and modifications also fall within the protection scope of the claims of this utility model.

Claims

1. A differential and common-mode integrated inductor, characterized in that, include: A magnetic core (10) comprising at least two winding regions and a magnetic conductor located between two adjacent winding regions; A copper busbar group (20) is provided in the winding area. The copper busbar group (20) includes multiple turns of copper busbars wound in the winding area, and the winding directions of the copper busbars in at least two of the copper busbar groups (20) are opposite. Insulating material (30) is disposed between the magnetic core (10) and the copper busbar group (20) and any adjacent copper busbar in the copper busbar group (20).

2. The differential and common-mode integrated inductor as described in claim 1, characterized in that, The number of turns of the copper busbar in each of the copper busbar groups (20) is N+1 / 2 turns.

3. The differential and common-mode integrated inductor as described in claim 1, characterized in that, The copper busbar group (20) includes a plurality of copper busbars connected in sequence, each of which is concentrically wound around the winding area in the circumferential direction.

4. The differential and common-mode integrated inductor as described in claim 3, characterized in that, The two adjacent copper busbars are connected by welding.

5. The differential and common-mode integrated inductor as described in claim 1, characterized in that, The winding area includes a first winding area and a second winding area, and the copper busbar group (20) includes a first copper busbar group (21) and a second copper busbar group (22), and the insulating material (30) includes a first insulating material (31) and a second insulating material (32). The first copper busbar group (21) is disposed in the first winding area, and the second copper busbar group (22) is disposed in the second winding area. The first copper busbar group (21) and the second copper busbar group (22) are arranged symmetrically. The first insulating material (31) is disposed in the first winding area, and the second insulating material (32) is disposed in the second winding area.

6. The differential and common-mode integrated inductor as described in claim 5, characterized in that, The magnetic core (10) includes a first magnetic core (11) and a second magnetic core (12), with the first magnetic core (11) and the second magnetic core (12) facing each other.

7. The differential and common-mode integrated inductor as described in claim 6, characterized in that, The left magnetic post of the first magnetic core (11) abuts against the left magnetic post of the second magnetic core (12) to form the first winding area. The right magnetic post of the first magnetic core (11) abuts against the right magnetic post of the second magnetic core (12) to form the second winding area. The center magnetic post of the first magnetic core (11) and the center magnetic post of the second magnetic core (12) abut against each other to form the magnetic conductor.

8. The differential and common-mode integrated inductor as described in claim 7, characterized in that, The outlines of the first magnetic core (11) and the second magnetic core (12) are both rectangular, and the shapes of the central magnetic post of the first magnetic core (11) and the central magnetic post of the second magnetic core (12) include rectangular and cylindrical shapes.

9. The differential / common mode integrated inductor as described in any one of claims 1-8, characterized in that, The insulating material is insulating paper.

10. The differential / common mode integrated inductor as described in any one of claims 1-8, characterized in that, Both ends of the copper busbar assembly (20) are provided with connecting through holes.

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