Power inductor assembly

Abstract

The utility model relates to the technical field of inverters, in particular to a power inductor assembly. The power inductor comprises a phase change radiator, a hollow phase change heat dissipation aluminum shell is arranged on the inner wall face of the phase change radiator, and a hollow cavity used for containing a power inductor body is formed in the phase change heat dissipation aluminum shell. A first printed circuit board is arranged at one end, far away from the phase change radiator, of the phase change heat dissipation aluminum shell, and a through hole in the first printed circuit board is matched with a winding outlet pin on the power inductor body; the first printed circuit board is fixedly connected with a second printed circuit board, and a conductive tab of the first printed circuit board is in contact with a conductive column of the second printed circuit board. The device solves the problems that the utilization rate of the internal space of the inverter is small, the difficulty of automatic assembly of the power inductor body is large, an outgoing cable of the power inductor body can generate electromagnetic interference on peripheral sensitive devices, and the influence of the electromagnetic interference cannot be accurately evaluated and improved through electromagnetic simulation.

Description

Technical Field

[0001] This utility model relates to the field of inverter technology, specifically a power inductor component. Background Technology

[0002] Power inductors are a crucial component of photovoltaic inverters. Their primary function is to filter high-frequency harmonics generated during DC-DC and DC-AC power conversion. They also convert electrical energy into magnetic field energy for storage, enhancing the inverter's short-term power output capability to accommodate loads with varying characteristics. Currently, the industry standard is to use cables to connect the power inductor windings to the printed circuit board for signal transmission.

[0003] The existing technology has the following shortcomings:

[0004] 1. Connecting cables occupy internal space in the inverter, reducing the inverter's power density;

[0005] 2. The presence of connecting cables increases the difficulty of automated assembly of power inductors;

[0006] 3. Power inductor cables contain many high-frequency harmonics, which can easily cause electromagnetic interference to surrounding sensitive devices along the wiring path.

[0007] 4. The cable is flexible, and the internal routing path of the cable is not unique and uncertain. Therefore, it is impossible to accurately assess and improve the impact of electromagnetic interference through electromagnetic simulation. Utility Model Content

[0008] To address the problems in related technologies, this utility model provides a power inductor component. This device solves the problems of low internal space utilization of inverters, difficulty in automated assembly of the power inductor body, electromagnetic interference caused by the outgoing cables of the power inductor body to surrounding sensitive devices, and the inability to accurately assess and improve the impact of electromagnetic interference through electromagnetic simulation.

[0009] To solve the above problems, the following technical solutions are provided:

[0010] This utility model discloses a power inductor assembly including a phase change heat sink. A hollow phase change heat sink aluminum shell is disposed on the inner wall of the phase change heat sink, and the phase change heat sink aluminum shell is fixedly fitted to the phase change heat sink. A hollow cavity for accommodating the power inductor body is disposed inside the phase change heat sink aluminum shell. A first printed circuit board is disposed at the end of the phase change heat sink aluminum shell away from the phase change heat sink. A through hole is disposed on the first printed circuit board, and the through hole is adapted to the winding lead on the power inductor body. A second printed circuit board is fixedly connected to the first printed circuit board. Outwardly protruding conductive electrode tabs are disposed on both sides of the first printed circuit board. Conductive posts are disposed on the second printed circuit board, and the conductive electrode tabs of the first printed circuit board are in contact with the conductive posts.

[0011] In the above solution, by setting up a first printed circuit board and a second printed circuit board, a phase-change heat sink is connected to the first printed circuit board, and the first printed circuit board is connected to the second printed circuit board to optimize the connection cable. The winding leads of the power inductor body are soldered to the first printed circuit board, and then the first printed circuit board is mounted to the second printed circuit board with screws, so that the conductive tabs of the first printed circuit board are in contact with the conductive posts of the second printed circuit board. At this time, since the winding leads of the power inductor body are already connected to the conductive tabs on the first printed circuit board through copper traces on the first printed circuit board, and the conductive tabs and the conductive posts on the second printed circuit board are electrically connected by screw fastening, the power inductor body winding is thus realized. The connection with the second printed circuit board (PCB) utilizes the first PCB to connect the power inductor winding to the second PCB, reducing cabling and significantly improving inverter space utilization. The absence of cables enables automated assembly of the power inductor, solving the problem of high difficulty in automated power inductor assembly. The connection between the power inductor's wiring and the first and second PCBs allows for maintaining appropriate distances from surrounding sensitive devices, preventing electromagnetic interference from the power inductor's outgoing cables. Using the first and second PCBs for power inductor routing allows for accurate modeling and simulation in electromagnetic simulation software to assess the impact of electromagnetic interference.

[0012] The first printed circuit board is provided with positioning holes, and the second printed circuit board is provided with positioning pins that are adapted to the positioning holes.

[0013] The above solution uses positioning holes and positioning pins to guide and limit the first printed circuit board when it is installed onto the second printed circuit board, thus solving the problem of positional deviation during placement.

[0014] The conductive electrode ear is provided with a first screw hole, and the conductive post is provided with a second screw hole. By passing a screw through the first screw hole and the second screw hole, the first printed circuit board and the second printed circuit board are fixedly connected.

[0015] In the above solution, the screw is passed through the first screw hole and the second screw hole by setting the first screw hole, thereby fixing the first printed circuit board and the second printed circuit board together.

[0016] The first printed circuit board has a potting port at one end.

[0017] The above solution uses a filling port for injecting thermally conductive silicone.

[0018] The first printed circuit board is located in the middle of the second printed circuit board.

[0019] The phase change radiator has heat dissipation fins on its outer wall surface.

[0020] The above solution uses heat dissipation fins to increase the heat dissipation area, thereby improving heat dissipation efficiency.

[0021] The above solution has the following advantages:

[0022] This invention optimizes the connection cable by using a first printed circuit board (PCB) and a second PCB, with a phase-change heat sink connected to the first PCB and the first PCB connected to the second PCB. The winding leads of the power inductor are soldered to the first PCB, and then the first PCB is mounted to the second PCB with screws. This ensures that the conductive tabs of the first PCB are in contact with the conductive posts of the second PCB. Since the winding leads of the power inductor are connected to the conductive tabs on the first PCB via copper traces, the electrical connection between the conductive tabs and the conductive posts on the second PCB is achieved by screw fastening. The connection between the power inductor winding and the second printed circuit board is achieved. Using the first printed circuit board to connect the power inductor winding and the second printed circuit board reduces cabling and significantly improves the inverter's space utilization. The absence of cables enables automated assembly of the power inductor. The connection between the power inductor's wiring and the first and second printed circuit boards allows for proper spacing from surrounding sensitive devices, preventing electromagnetic interference from the power inductor's outgoing cables. Using the first and second printed circuit boards for power inductor routing allows for accurate modeling and simulation in electromagnetic simulation software to assess the impact of electromagnetic interference. Attached Figure Description

[0023] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein:

[0024] Figure 1 An exploded view of a power inductor component;

[0025] Figure 2 This is a schematic diagram of the structure of a phase change heat sink, a phase change heat sink aluminum shell, a power inductor body, and a first printed circuit board in a power inductor assembly.

[0026] Figure 3 This is a schematic diagram of the structure of a power inductor body and a first printed circuit board in a power inductor assembly;

[0027] Figure 4 This is an enlarged schematic diagram of part A in a power inductor component;

[0028] Figure 5 This is an enlarged schematic diagram of part B in a power inductor component;

[0029] Explanation of reference numerals in the attached diagram: 1. Phase change heat sink; 2. Phase change heat sink aluminum shell; 3. Power inductor body; 4. First printed circuit board; 5. Through hole; 6. Wire lead; 7. Second printed circuit board; 8. Conductive post; 9. Conductive electrode ear; 10. Positioning hole; 11. Positioning pin; 12. First screw hole; 13. Screw; 14. Glue inlet; 15. Heat sink fins. Detailed Implementation

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0031] In specific embodiment 1, such as Figure 2 , 3As shown, a power inductor assembly of this utility model includes a phase change heat sink 1. A hollow phase change heat sink aluminum shell 2 is disposed on the inner wall of the phase change heat sink 1. The phase change heat sink aluminum shell 2 is fixedly fitted to the phase change heat sink 1. A hollow cavity for accommodating the power inductor body 3 is disposed inside the phase change heat sink aluminum shell 2. A first printed circuit board 4 is disposed at the end of the phase change heat sink aluminum shell 2 away from the phase change heat sink 1. A through hole 5 is disposed on the first printed circuit board 4. The through hole 5 is adapted to the winding lead 6 on the power inductor body 3. A second printed circuit board 7 is fixedly connected to the first printed circuit board 4. The printed circuit board 4 is located in the middle of the second printed circuit board 7. Both sides of the first printed circuit board 4 have outwardly protruding conductive electrode ears 9. The second printed circuit board 7 has conductive posts 8. The conductive electrode ears 9 of the first printed circuit board 4 contact the conductive posts 8. A phase-change heat sink 1 is used to connect to the first printed circuit board 4, and the first printed circuit board 4 is connected to the second printed circuit board 7, thereby optimizing the connection cable. The winding leads 6 of the power inductor body 3 are soldered to the first printed circuit board 4, and then the first printed circuit board 4 is mounted on the second printed circuit board 7 using screws 13. This allows the conductive tabs 9 of the first printed circuit board 4 to contact the conductive posts 8 of the second printed circuit board 7. Since the winding leads of the power inductor body 3 are connected to the conductive tabs 9 on the first printed circuit board 4 via copper traces, the conductive tabs 9 and the conductive posts 8 on the second printed circuit board 7 are electrically connected by screws 13, thus achieving the connection between the winding of the power inductor body 3 and the second printed circuit board 7. Using the first printed circuit board 4 to connect the winding of the power inductor body 3 and the second printed circuit board 7 helps reduce cabling and greatly improves efficiency. This improves the space utilization of the inverter; the absence of cables allows for automated assembly of the power inductor body 3, significantly reducing the difficulty of automated assembly; the wiring of the power inductor body 3, connected to the first printed circuit board 4 and the second printed circuit board 7, allows for appropriate spacing from surrounding sensitive devices, preventing electromagnetic interference from the power inductor body 3's outgoing cables; using the first printed circuit board 4 and the second printed circuit board 7 to complete the wiring of the power inductor body 3 allows for accurate modeling and simulation in electromagnetic simulation software to assess the impact of electromagnetic interference.

[0032] like Figure 4 As shown, the conductive electrode ear 9 is provided with a first screw hole 12, and the conductive post 8 is provided with a second screw hole. By passing the screw 13 through the first screw hole 12 and the second screw hole, the first printed circuit board 4 and the second printed circuit board 7 are fixedly connected.

[0033] The first printed circuit board 4 has a potting port 14 at one end for filling with thermally conductive silicone.

[0034] In a specific embodiment 2, such as Figure 1 , 4 As shown, the difference between this embodiment and embodiment 1 is that the first printed circuit board 4 in this embodiment is provided with a positioning hole 10, and the second printed circuit board 7 is provided with a positioning pin that matches the positioning hole 10. When the first printed circuit board 4 is installed on the second printed circuit board 7, the positioning pin is used for guidance and limiting, so that the position will not deviate during the placement process.

[0035] In a specific embodiment 3, such as Figure 2 As shown, the difference between this embodiment and embodiments 1 and 2 is that the phase change radiator 1 in this embodiment is provided with heat dissipation fins 15 on its outer wall surface to increase the heat dissipation area and thus improve the heat dissipation efficiency.

[0036] During operation, the winding leads 6 on the power inductor body 3 are first soldered onto the first printed circuit board 4. The phase change heat sink 2 is fixedly connected to the phase change heat sink 1. Then, the power inductor body 3 is flipped onto the phase change heat sink 2. Thermally conductive silicone is potted through the potting port 14 to form the first component. The first component is placed on the second printed circuit board 7 so that the first printed circuit board 4 and the second printed circuit board 7 abut against each other. The positioning hole 10 is matched with the positioning pin to guide and limit the first printed circuit board 4. Then, the screw 13 passes through the first screw hole 12 and the second screw hole in sequence to fix the first printed circuit board 4 and the second printed circuit board 7, thus forming a wireless power inductor component.

[0037] In the description of this utility model, it should be understood that the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. In the description of this utility model, unless otherwise specified and limited, it should be noted that the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components, and can be direct connections or indirect connections through an intermediate medium. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0038] Obviously, the above embodiments are merely examples for clear illustration and are not intended to limit the implementation. For those skilled in the art, other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all implementation methods here, and any obvious variations or modifications derived therefrom are still within the protection scope of this utility model.

Claims

1. A power inductance assembly, characterized by The utility model provides a phase change radiator (1), the inner wall surface of phase change radiator (1) is provided with hollow phase change radiator aluminum shell (2), phase change radiator aluminum shell (2) is fixedly matched with phase change radiator (1), hollow cavity for accommodating power inductance body (3) is arranged in phase change radiator aluminum shell (2) inside, first printed circuit board (4) is arranged at the end of phase change radiator aluminum shell (2) away from phase change radiator (1), and the through hole (5) is arranged on first printed circuit board (4), and the through hole (5) is adapted with the winding out foot (6) on power inductance body (3), and the second printed circuit board (7) is fixedly connected on first printed circuit board (4), and the both sides of first printed circuit board (4) are provided with the conductive lug (9) that protrudes outward, and the conductive column (8) is arranged on the second printed circuit board (7), and the conductive lug (9) of first printed circuit board (4) is in contact with the conductive column (8).

2. A power inductor assembly as claimed in claim 1, wherein, The first printed circuit board (4) is provided with a positioning hole (10), and the second printed circuit board (7) is provided with a positioning pin (11) matched with the positioning hole (10).

3. A power inductor assembly as claimed in claim 1, wherein, The conductive lug (9) is provided with a first screw hole (12), and the conductive column (8) is provided with a second screw hole, and the first printed circuit board (4) is fixedly connected with the second printed circuit board (7) by screwing (13) through the first screw hole (12) and the second screw hole.

4. A power inductor assembly as claimed in claim 1, wherein, The first printed circuit board (4) is provided with a glue pouring port (14) at one end.

5. A power inductor assembly as claimed in claim 1, wherein, The first printed circuit board (4) is located in the middle of the second printed circuit board (7).

6. A power inductor assembly as claimed in claim 1, wherein, The outer wall surface of the phase change radiator (1) is provided with a heat dissipation fin (15).

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