Differential and common mode integrated inductor

Abstract

The utility model discloses a differential and common mode integrated inductor, which comprises a magnetic core and at least two inductance coils, the at least two inductance coils are respectively wound on the magnetic core, and each inductance coil comprises a plurality of first line segments, two second line segments and a plurality of third line segments. Through segmented design of the first line segment, the second line segment and the third line segment of the inductance coil, the shapes of the first line segment, the second line segment and the third line segment can be processed in a segmented mode to be attached to the outer wall face of a magnetic core under the conditions that the line diameter of a copper bar reaches 10 mm or above, and the copper bar is thick and high in hardness. And the connecting ends of the first line segment, the second line segment and the third line segment are welded according to the arrangement to form a complete inductance coil, so that the whole inductance coil is closer to the magnetic core. The problem that it is strenuous to wind the coil by pulling the copper bar manually is solved. And the problem of large overall structure size caused by large gap between the coil and the magnetic core which are mechanically and automatically wound is also solved, the size of the differential and common mode integrated inductor is reduced, and the space utilization rate is improved.

Description

Technical Field

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

[0002] Due to the needs of people's work and life, the demand for power electronic equipment is increasing. However, almost all power supply circuits generate common-mode and differential-mode electromagnetic interference signals. Usually, power supply circuits are equipped with common-mode filter inductors and differential-mode filter inductors to reduce or suppress common-mode and differential-mode interference signals, so that the power supply circuit meets the requirements of electromagnetic compatibility.

[0003] As electronic components evolve towards miniaturization, thinner mounting, lower electromagnetic interference, and higher efficiency, inductors are inevitably following this trend. Currently, most inductors on the market consist of three main parts: a coil, a magnetic core, and leads. The coil is the core component of the inductor, used to store electromagnetic energy, and is typically made of copper.

[0004] When the current in a circuit exceeds a certain threshold (which depends on the specific circuit design and safety standards), copper strips of 50 square millimeters or more are required to ensure the safe and stable operation of the circuit. When the copper strip diameter reaches 10 millimeters or more, the copper strip is very thick and has high hardness, making it very laborious and difficult to wind manually. On the other hand, the current automated mechanical winding method results in a large gap between the wound coil and the magnetic core, and a large coil structure, leading to a large overall structure volume and low space utilization. Utility Model Content

[0005] To address the shortcomings of existing technologies, this invention provides a differential and common-mode integrated inductor.

[0006] This utility model discloses a differential and common-mode integrated inductor, comprising: a magnetic core and at least two inductor coils, the at least two inductor coils being wound on the magnetic core respectively, each inductor coil comprising multiple first segments, two second segments, and multiple third segments. The multiple first segments and two second segments are all disposed along the outer peripheral wall of the magnetic core, and the multiple first segments are arranged sequentially between two second segments. Each first segment has a first end and a second end, and each second segment has a long side and a short side. In two adjacent first segments, the first end of one first segment is connected to the second end of the other first segment through a third segment, wherein the short side of one second segment is connected to the second end of the adjacent first segment through a third segment, and the short side of the other second segment is connected to the first end of the adjacent first segment through a third segment, so that at least two inductor coils can be wound on the magnetic core respectively.

[0007] Preferably, it also includes a magnetic conductive sheet, which is placed in the middle of the magnetic core and is located between two adjacent inductor coils and is magnetically connected to the magnetic core.

[0008] Preferably, it also includes an upper magnetic core shell and a lower magnetic core shell, which are closed together, with the magnetic core embedded between the upper and lower magnetic core shells, and multiple inductor coils wound on the upper and lower magnetic core shells.

[0009] Preferably, the system also includes a number of limiting frames equal to the number of inductor coils, with each limiting frame located on the upper shell of the magnetic core and each limiting frame containing one inductor coil.

[0010] Preferably, each limiting frame has multiple coil slots and multiple frame feet, with the first line segment and the second line segment placed in the coil slots respectively.

[0011] Preferably, it also includes a base plate, on which a third line segment groove, a pin hole and a skeleton foot hole are provided. Each third line segment is provided in each third line segment groove, a long side is passed through each pin hole, and a skeleton foot is passed through each skeleton foot hole.

[0012] Preferably, there are two inductor coils, which are wound opposite to each other on the magnetic core.

[0013] Preferably, the magnetic core is shaped like a flat racetrack.

[0014] Preferably, the first line segment is U-shaped, the second line segment is η-shaped, and the third line segment includes two parallel line segments and a connecting line segment. The two parallel line segments are placed in a staggered parallel position and have a height difference. The two parallel line segments are connected by the connecting line segment at their closest ends.

[0015] The beneficial effects of this utility model are as follows: Compared with the prior art, this differential common-mode integrated inductor includes a magnetic core and at least two inductor coils. The at least two inductor coils are respectively wound on the magnetic core. Through the segmented design of the first, second, and third segments of the inductor coils, even when the copper wire diameter is more than 10 mm, the copper wire is very thick and has high hardness, the shapes of the first, second, and third segments can be processed in segments to fit the outer wall of the magnetic core. Then, the first, second, and third segments are arranged and welded together to form a complete inductor coil, making the inductor coil fit closer to the magnetic core. This solves the problem of the laboriousness of manually drawing copper wire to wind the inductor coil to fit the magnetic core. It also solves the problem of the large gap between the inductor coil and the magnetic core in mechanically automated winding, which makes it impossible for the inductor coil to fit the entire outer wall of the magnetic core, resulting in a large overall structure volume. With the same copper strip fill rate when winding the inductor coil, the inductor coil of this design fits the magnetic core better, which reduces the volume of the differential and common mode integrated inductor and improves space utilization. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0017] Figure 1 An exploded view of the overall structure of a differential common-mode integrated inductor;

[0018] Figure 2 A 3D view of a differential and common-mode integrated inductor;

[0019] Figure 3 The diagram shows the inductor coil structure of a differential and common-mode integrated inductor.

[0020] Figure 4 Exploded view of the inductor coil for a differential common-mode integrated inductor;

[0021] Figure 5 This is a schematic diagram of the base plate for a differential common-mode integrated inductor.

[0022] Figure Labels

[0023] 1. Magnetic core;

[0024] 2. Inductor coil; 21. First segment; 211. First end; 212. Second end; 22. Second segment; 221. Long side; 222. Short side; 23. Third segment; 231. Parallel segment; 232. Connecting segment;

[0025] 3. Magnetic conductive sheet;

[0026] 4. Upper shell of magnetic core; 5. Lower shell of magnetic core;

[0027] 6. Limiting frame; 61. Coil slot; 62. Frame feet;

[0028] 7. Base plate; 71. Third segment slot; 72. Pin hole; 73. Skeleton foot hole. Detailed Implementation

[0029] The following drawings will disclose several embodiments of this utility model. For clarity, many practical details will be described in the following description. However, it should be understood that these practical details should not be used to limit this utility model. That is, in some embodiments of this utility model, these practical details are not essential. In addition, for the sake of simplicity, some conventional structures and components will be shown in the drawings in a simple schematic manner.

[0030] Furthermore, in this utility model, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the utility model. They are merely used to distinguish components or operations described with the same technical terms and should not be construed as indicating or implying their relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of various embodiments can be combined with each other, but only if they are feasible for those skilled in the art. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0031] Please see Figures 1 to 2 As shown, Figure 1 This is an exploded view of the overall structure of a differential and common-mode integrated inductor. Figure 2 This is a perspective view of a differential-common-mode integrated inductor. This embodiment discloses a differential-common-mode integrated inductor, including a magnetic core 1 and at least two inductor coils 2, the at least two inductor coils 2 being wound on the magnetic core 1.

[0032] Please see Figure 3 and Figure 4 As shown, Figure 3 The diagram shows the inductor coil structure of a differential and common-mode integrated inductor. Figure 4 This is an exploded view of the inductor coil of a differential common-mode integrated inductor. In this embodiment, each inductor coil 2 includes multiple first segments 21, two second segments 22, and multiple third segments 23. The multiple first segments 21 and the two second segments 22 are all disposed on the magnetic core 1 along the outer peripheral wall of the magnetic core 1, and the multiple first segments 21 are arranged sequentially between the two second segments 22. Each first segment 21 includes a first end 211 and a second end 212, and the second segment 22 includes a long side 221 and a short side 222. When the first segment 21, the second segment 22, and the third segment 23 are wound onto the magnetic core 1, in two adjacent first segments 21, the first end 211 of one first segment 21 is connected to the second end 212 of the other first segment 21 through a third segment 23, and the short side 222 of one second segment 22 is connected to the second end 212 of the adjacent first segment 21 through a third segment 23, and the short side 222 of the other second segment 22 is connected to the first end 211 of the adjacent first segment 21 through a third segment 23, so that at least two inductor coils 2 can be wound onto the magnetic core 1 respectively.

[0033] In other words, in order to ensure that at least two inductor coils 2 are wound on the magnetic core 1, the short side of a second segment 22 is connected to the first end 211 of a first segment 21 through a third segment 23. Then, the second end 212 of the first segment 21 is connected to the first end 211 of the next first segment 21 through a third segment 23. Then, the second end 212 of the next first segment 21 is connected to the first end 211 of another first segment 21 through a third segment 23. This process is repeated multiple times, with the second end 212 of one first segment 21 connected to the first end 211 of another first segment 21 through a third segment 23. Finally, the second end 212 of the last remaining first segment 21 is connected to the short side of another second segment 22 through a third segment 23, thus forming a complete inductor coil 2.

[0034] In practical applications, at least two inductor coils 2 are wound on the magnetic core 1. Each inductor coil 2 includes multiple first segments 21, two second segments 22, and multiple third segments 23. The inductor coil 2 is wound on the magnetic core 1 through multi-segment connections of the first segments 21, second segments 22, and third segments 23. When the copper wire diameter reaches 10 mm or more, the copper wire is thick and has high hardness. Through the segmented design of the inductor coil, the first segments 21, second segments 22, and third segments 23 can be processed into shapes that fit the outer wall of the magnetic core 1. Then, the first segments, second segments, and third segments are arranged and welded together to form a complete inductor coil. This makes the inductor coil fit the magnetic core 1 more closely, thus solving the problem of the laboriousness of manually drawing copper wire to wind the inductor coil to fit the magnetic core. It also solves the problem of large gaps between the inductor coil and the magnetic core in mechanically automated winding, which prevents the inductor coil from fitting the entire outer wall of the magnetic core, resulting in a large overall structural volume. With the same copper strip fill rate for winding the inductor coil, the volume of the differential common-mode integrated inductor is reduced, and the space utilization is improved.

[0035] In this embodiment, the magnetic core 1 is made of high-permeability ferrite, but it can also be made of iron powder core material, flexible magnetic core material, etc. The inductor coil 2 is made of copper strip, which has the characteristics of good conductivity, heat resistance, corrosion resistance, high ductility, and high mechanical strength.

[0036] When there are two inductor coils 2, they are wound on opposite sides of the magnetic core 1. When there are three inductor coils 2, they are wound circumferentially on the magnetic core 1 with equal spacing. When there are four inductor coils 2, they can be wound in two pairs on opposite sides of the magnetic core 1, or they can be wound circumferentially on the magnetic core 1 with equal spacing. The number of inductor coils 2 can also be more, depending on specific requirements.

[0037] In order to optimize the magnetic potential distribution, reduce the loss of the magnetic core 1 and improve heat dissipation, when at least two inductor coils 2 are wound on the magnetic core 1, the number of turns of each inductor coil 2 is kept the same and they are symmetrically distributed on the magnetic core 1.

[0038] Furthermore, review Figure 1 As shown, in this embodiment, the differential-common mode integrated inductor also includes a magnetic sheet 3. The magnetic sheet 3 is placed in the middle of the magnetic core 1 and located between two adjacent inductor coils 2. The two ends of the magnetic sheet 3 are magnetically connected to the magnetic core 1, thereby achieving a larger differential-mode inductance. When the inductor coils 2 are completely symmetrical, the resulting differential-mode inductance balance is optimal. This structure is simple, low-cost, and has good performance, which can better meet market demands.

[0039] The magnetic conductor 3 is made of iron-silicon material, which has the characteristics of high melting point, strong corrosion resistance, magnetism, good conductivity and excellent mechanical properties. Iron-silicon-aluminum material can also be used. The size of the differential mode inductor can be adjusted by adjusting the material and size of the magnetic conductor 3.

[0040] Furthermore, review Figure 1 As shown, in this embodiment, the differential and common mode integrated inductor also includes a magnetic core upper shell 4 and a magnetic core lower shell 5. The magnetic core upper shell 4 covers the magnetic core lower shell 5, and the magnetic core 1 is sleeved between the magnetic core upper shell 4 and the magnetic core lower shell 5. Thus, the entire structure after the magnetic core upper shell 4 and the magnetic core lower shell 5 are covered has at least two inductor coils 2 wound on it.

[0041] In this example, the lower shell 5 of the magnetic core has a groove with the same shape as the magnetic core 1, allowing the magnetic core 1 to be placed in the groove. The upper shell 4 of the magnetic core also has a groove with the same shape as the magnetic core 1. The upper shell 4 can be fastened onto the magnetic core 1 and then closed onto the lower shell 5. The upper shell 4 and the lower shell 5 are joined together so that the magnetic core 1 is completely embedded within them, that is, the upper shell 4 and the lower shell 5 enclose and seal the magnetic core 1. The upper shell 4 and the lower shell 5 are made of existing epoxy resin material, which serves as an insulating encapsulation, or they can be made of plastic material.

[0042] Furthermore, in this embodiment, the differential and common-mode integrated inductor also includes a limiting frame 6. The number of limiting frames 6 is the same as the number of inductor coils 2. The limiting frames 6 are disposed on the upper shell 4 of the magnetic core. At least two inductor coils 2 are wound on the upper shell 4 and the lower shell 5 of the magnetic core, and the portion wound on the upper shell 4 is placed in the limiting frame 6. Each limiting frame 6 contains one inductor coil 2. The limiting frame 6 is made of common epoxy resin material, but other insulating materials such as plastic can also be used. Its main function is to stabilize and limit the inductor coils 2 after winding.

[0043] Specifically, each limiting frame 6 has multiple coil slots 61 and multiple frame feet 62. The first line segment 21 and the second line segment 22 are placed in the coil slots 61 respectively, and the frame feet 62 extend out of the bottom of the magnetic core lower shell 5. In this embodiment, the multiple coil slots 61 of the limiting frame 6 are set according to the required number of first line segments 21 and second line segments 22 and are placed in a one-to-one correspondence. The width of the coil slots 61 matches the width of the copper strip, so that the first line segments 21 and second line segments 22 are placed stably in the coil slots 61 and are not easy to move. The frame feet 62 extending out of the bottom of the magnetic core lower shell 5 can be used to fix it in the required position.

[0044] Please see Figure 5 As shown, Figure 5 This is a schematic diagram of the base plate of the differential common-mode integrated inductor. In this embodiment, the differential common-mode integrated inductor also includes a base plate 7. The base plate 7 has multiple third segment slots 71, multiple pin holes 72, and multiple skeleton foot holes 73. Each third segment slot 71 contains a third segment 23, and the long side 221 of the second segment 22 passes through the pin hole 72. Each skeleton foot 62 exits from one skeleton foot hole 73. In this example, the magnetic core 1 is placed on the base plate 7 and housed within the upper shell 4 and lower shell 5 of the magnetic core. The shape and size of the third segment slots 71 are consistent with the third segment 23. All third segments 23 are placed in the third segment slots 71 and welded to the first segment 21 and the second segment 22 wound on the magnetic core 1 to form a complete inductor coil 2. The pin holes 72 are opened corresponding to the positions of the long side 221 of the second segment 22, and the long side 221 of each second segment 22 can pass through the pin hole 72 to form a pin. The frame foot hole 73 is opened corresponding to the position of the frame foot 73. The frame foot 73 passes through the frame foot hole 73 and is fixed, thereby stabilizing the inductor coil 2 on the frame 7.

[0045] When the current in the circuit exceeds a certain threshold, copper strips of 50 square millimeters or more are required to ensure the safe and stable operation of the circuit. That is, when the diameter of the copper strip needs to reach more than 10 millimeters, and the copper strip is very thick and has high hardness, at least two inductor coils 2 are wound on the magnetic core 1. Each inductor coil 2 includes multiple first segments 21, two second segments 22, and multiple third segments 23. Through the segmented design of the first segments 21, second segments 22, and third segments 23, the first segments 21, second segments 22, and third segments 23 can be more easily processed into shapes that fit the magnetic core 1, and then combined and welded together to form a complete inductor coil 2. That is, the segmented design of the inductor coil 2 makes the position of the inductor coil 2 closer to the magnetic core 1, thereby solving the problem that it is very laborious to manually pull copper strips to wind the inductor coil 2, and also solving the problem that the gap between the inductor coil wound by mechanical automation is large, resulting in a large overall structure volume. With the same copper strip fill rate, the design of the inductor coil 2 and the magnetic core 1 is more closely fitted, which makes the differential and common mode integrated inductor smaller in size, thereby improving the space utilization.

[0046] The magnetic core 1 is placed between the upper shell 4 and the lower shell 5, so that the upper shell 4 and the lower shell 5 cover and encapsulate the magnetic core 1, which serves as insulation and improves the safety of use.

[0047] Each inductor coil 2 has multiple first segments 21 and two second segments 22, which are placed in multiple coil slots 61 on the frame 7. The third segment 23 is placed in the third segment slot 71 on the base plate 1. The third segment 23 is soldered to the first segments 21 and the second segments 22. The coil slots 61 and the third segment slots 71 limit and fix the two inductor coils 2, making them less likely to move during use. The long side 221 of the second segment 22 passes through the pin hole 72 to form a pin, which is then soldered onto the circuit board. The frame foot 73 passes through the frame foot hole 73 for fixation, making the whole structure more stable.

[0048] A magnetic sheet 3 is placed in the middle of the magnetic core 1. The magnetic sheet 3 is located between two adjacent inductor coils 2 and is magnetically connected to the magnetic core 1, thereby achieving a large differential mode inductance. When the distribution of the inductor coils 2 on the magnetic core 1 is completely symmetrical, the resulting differential mode inductance balance is optimal. The size of the differential mode inductance can be adjusted by adjusting the material and size of the magnetic sheet 3. This structure is simple, low-cost, can be automated, has high production efficiency, and good performance, better meeting market demands.

[0049] Review Figure 1 and Figure 4As shown, in this embodiment, when there are two inductor coils 2, the two inductor coils 2 are wound on opposite sides of the magnetic core 1 respectively. The number of turns of each inductor coil 2 is the same and they are symmetrically distributed, which can optimize the magnetic potential distribution, reduce the loss of the magnetic core 1 and improve heat dissipation.

[0050] Furthermore, the magnetic core 1 is flat and racetrack-shaped, with two inductor coils 2 wound on the opposite long sides of the magnetic core 1.

[0051] Specifically, each inductor coil 2 includes a first segment 21, a second segment 22, and a third segment 23. The first segment 21 is a U-shape with the first end 211 and the second segment 212 being parallel and equal. The second segment 22 is an η-shape with the long side 221 and the short side 222 being parallel. The third segment 23 includes two parallel segments 231 and a connecting segment 232. The two parallel segments 231 are placed in parallel with a staggered arrangement and have a height difference. The near ends of the two parallel segments 231 are connected by the connecting segment 232. When the magnetic core 1 is a flat racetrack shape, the cross-sectional shape of its two opposite long sides along the winding direction of the inductor coil 2 is a rounded rectangle. When the first segment 21 is U-shaped, the second segment 22 is η-shaped, and the third segment 23 is connected and welded to form a complete inductor coil 2, the cross-sectional shape of its winding matches the cross-sectional shape of the magnetic core 1 along the winding direction of the inductor coil 2. That is, the segmented design of the inductor coil 2 allows the inductor coil 2 and the magnetic core 1 to be positioned close together. Moreover, the processing of the first segment 21, the second segment 22, and the third segment 23 can be automated, and then welded together. This solves the problem that it is very laborious to manually draw copper strips to wind the inductor coil 2 to fit the magnetic core 1, and also solves the problem of large gaps between the inductor coil 2 and the magnetic core 1 wound by mechanical automation. Under the same copper strip fill rate, the design of the inductor coil 2 and the magnetic core 1 being more closely fitted makes the size of the differential and common mode integrated inductor smaller, thereby improving the space utilization rate.

[0052] The above description is merely an embodiment of this utility model and is not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of this utility model should be included within the scope of the claims of this utility model.

Claims

1. A differential-common-mode integrated inductor, characterized in that, include: A magnetic core (1) and at least two inductor coils (2), the at least two inductor coils (2) being wound on the magnetic core (1); each inductor coil (2) includes a plurality of first segments (21), two second segments (22) and a plurality of third segments (23); the plurality of first segments (21) and the two second segments (22) are all disposed on the magnetic core (1) along the outer peripheral wall of the magnetic core (1), and the plurality of first segments (21) are arranged sequentially between the two second segments (22); each first segment (21) has a first end (211) and a second end (212), and each second segment (22) has a long side (221) and a short side (222); In two adjacent first line segments (21), the first end (211) of one first line segment (21) is connected to the second end (212) of the other first line segment (21) through a third line segment (23), wherein the short side (222) of one second line segment (22) is connected to the second end (212) of the adjacent first line segment (21) through a third line segment (23), and the short side (222) of the other second line segment (22) is connected to the first end (211) of the adjacent first line segment (21) through a third line segment (23), so that at least two inductor coils (2) can be wound on the magnetic core (1) respectively.

2. The differential-common-mode integrated inductor according to claim 1, characterized in that, It also includes a magnetic sheet (3), which is placed in the middle of the magnetic core (1). The magnetic sheet (3) is located between two adjacent inductor coils (2) and is magnetically connected to the magnetic core (1).

3. The differential-common-mode integrated inductor according to claim 1, characterized in that, It also includes an upper magnetic core shell (4) and a lower magnetic core shell (5), the upper magnetic core shell (4) and the lower magnetic core shell (5) are closed together, the magnetic core (1) is embedded between the upper magnetic core shell (4) and the lower magnetic core shell (5), and a plurality of inductor coils (2) are wound on the upper magnetic core shell (4) and the lower magnetic core shell (5).

4. The differential-common-mode integrated inductor according to claim 3, characterized in that, It also includes the same number of limiting frames (6) as the inductor coils (2), each of the limiting frames (6) is located on the upper shell (4) of the magnetic core, and each of the limiting frames (6) contains one inductor coil (2).

5. The differential-common-mode integrated inductor according to claim 4, characterized in that, Each of the limiting skeletons (6) has multiple coil slots (61) and multiple skeleton feet (62). The first line segment (21) and the second line segment (22) are placed in the coil slots (61) respectively, and the multiple skeleton feet (62) protrude from the lower shell (5) of the magnetic core.

6. The differential-common-mode integrated inductor according to claim 4, characterized in that, It also includes a base plate (7), on which a plurality of third line grooves (71), a plurality of pin holes (72) and a plurality of skeleton foot holes (73) are provided. Each of the third line grooves (71) is provided with a third line segment (23), each of the pin holes (72) is provided with a long side (221), and each of the skeleton foot holes (73) is provided with a skeleton foot (62).

7. The differential-common-mode integrated inductor according to claim 1, characterized in that, The number of inductor coils (2) is two, and the two inductor coils (2) are wound on the magnetic core (1) opposite to each other.

8. The differential-common-mode integrated inductor according to claim 1, characterized in that, The magnetic core (1) is flat and racetrack shaped.

9. The differential-common-mode integrated inductor according to claim 1, characterized in that, The first line segment (21) is U-shaped, the second line segment (22) is η-shaped, and the third line segment (23) includes two parallel line segments (231) and a connecting line segment (232). The two parallel line segments (231) are placed in parallel with a staggered height difference, and the two parallel line segments (231) are connected by a connecting line segment (232) at their closest ends.

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