Ultrathin PFC inductor with LLC resonant topology

Abstract

The utility model discloses an ultrathin PFC (Power Factor Correction) inductor with LLC (Logical Link Control) resonant topology. In order to solve the problems that a traditional annular PFC inductor is low in window utilization rate, large in finished product structure, high in cost and poor in EMI effect, the inductor adopts a special ER type high-flux alloy magnetic core, a winding is of a flat wire winding structure, and a lead is subjected to forming treatment to form an SMT mounting pin. The inductor is large in power density, is suitable for 500W-6KW PFC, and is reduced by 1 / 3-1 / 2 in size compared with a traditional structure. The magnetic core can shield the copper wire winding, electromagnetic radiation is effectively reduced, the bottom and the top are flat, and sufficient heat dissipation is facilitated. In application scenarios with high power density and strict volume requirements, such as server power supplies, industrial high-power equipment power supplies and other fields, the power supply has significant advantages, and can improve the equipment performance, reduce the cost and improve the electromagnetic compatibility.

Description

TECHNICAL FIELD

[0001] The utility model relates to inductance manufacturing technical field especially relates to a kind of PFC inductance of ultra-thin LLC resonant topology. BACKGROUND

[0002] LLC topology is widely used in high-power power supply structure field due to its low switching loss advantage. In many devices requiring efficient power conversion, such as server power supply, industrial automation equipment power supply, LLC topology plays a key role and provides strong support for stable operation of the device.

[0003] However, the traditional ring PFC inductance has many drawbacks in practical application. From the perspective of structural design, the window utilization rate of ring PFC inductance is low. This means that in a limited space, the window area cannot be fully utilized for winding winding, which limits the number of turns and affects the performance of the inductor. Under the same power demand, the size of the magnetic core has to be increased to compensate for this defect, which directly leads to a large finished product structure.

[0004] For example, in some data center server power supplies with extremely high space layout requirements, the traditional ring PFC inductance occupies a large space, making it difficult to further reduce the overall size of the power module, which is not conducive to the miniaturization design of the device. At the same time, the larger finished product structure means that more raw materials, including magnetic materials and wires, are needed, which undoubtedly increases production costs. Not only that, but the larger volume also increases transportation costs and causes additional economic burden in the logistics link.

[0005] In addition, due to the structural characteristics of the traditional ring PFC inductance, there are deficiencies in electromagnetic shielding, which can easily cause electromagnetic interference (EMI). In today's environment where electronic devices are intensively used, electromagnetic interference problems can affect the normal operation of other electronic devices in the surrounding area, reducing the stability and reliability of the entire system. For example, in the field of medical devices, aerospace electronic devices and other fields with strict requirements on electromagnetic environment, the electromagnetic interference problem of traditional ring PFC inductance has become a major obstacle to its application. SUMMARY

[0006] The utility model aims at solving the shortcomings in the prior art and provides a kind of PFC inductance of ultra-thin LLC resonant topology.

[0007] To achieve the above purpose, the utility model adopts the following technical solutions:

[0008] A kind of PFC inductance of ultra-thin LLC resonant topology, including ER type high-flux alloy material magnetic core;Winding formed by flat wire winding structure;Lead wire formed by molding treatment SMT mounting pin.

[0009] Preferably, the magnetic core is used to shield the winding.

[0010] Preferably, the bottom and the top of the inductor are flat structures.

[0011] Further, the inductor is suitable for PFC power range of 500W-6KW.

[0012] The beneficial effects of the present application are as follows:

[0013] 1. The PFC inductor for ultra-thin LLC topology provided by the present application adopts a special ER type high magnetic flux alloy material magnetic core and a flat wire winding structure, has the following advantages: the power density is greatly improved, the volume is reduced by 1 / 3-1 / 2 compared with the traditional structure, can meet the PFC demand of 500W-6KW, effectively reduces the space occupation; the shielding effect of the magnetic core on the copper wire winding significantly reduces the electromagnetic radiation and improves the electromagnetic compatibility; the flat structure design of the bottom and the top is beneficial to fully utilize the heat dissipation and ensure the stability of the inductor in high power operation, and is especially suitable for application scenarios with high volume requirement and high power density demand.

[0014] The above description is only a summary of the technical scheme of the present application, in order to more clearly understand the technical means of the present application, the content of the specification can be implemented, and in order to make the above and other purposes, characteristics and advantages of the present application more obvious and easy to understand, the following preferred embodiments are described in detail, and the accompanying drawings are as follows. BRIEF DESCRIPTION OF DRAWINGS

[0015] Fig. 1 The present application provides a magnetic core shape structure diagram of a PFC inductor for an ultra-thin LLC resonance topology;

[0016] Fig. 2 The present application provides a finished product shape structure diagram of a PFC inductor for an ultra-thin LLC resonance topology.

[0017] In the figure: 1, magnetic core; 2, winding; 3, lead. DETAILED DESCRIPTION

[0018] The technical scheme in the embodiments of the present application will be described in detail below, obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments.

[0019] Embodiment 1, refer to Figs. 1-2 A PFC inductor for an ultra-thin LLC resonance topology, comprising an ER type high magnetic flux alloy material magnetic core 1; a winding 2 formed in a flat wire winding structure; a lead 3 formed into an SMT mounting pin through a molding process.

[0020] In this embodiment, the magnetic core 1 is used to shield the winding 2, and the bottom and top of the inductor are flat structures, and the inductor is suitable for PFC power range of 500W-6KW.

[0021] The working principle of the embodiment: in the power supply system of LLC resonance topology, this ultra-thin PFC inductor plays a key role. Its working principle is based on the law of electromagnetic induction, and power factor correction and electric energy conversion are realized through the cooperative work of magnetic core and winding.

[0022] When the alternating current power is connected to the circuit, the current flows through the winding wound by flat wire. Since the winding is wound around the magnetic core made of ER type high magnetic flux alloy material, according to the principle of electromagnetic induction, the change of current will generate alternating magnetic field in the magnetic core. The magnetic core made of high magnetic flux alloy material has good magnetic conductivity, which can efficiently gather and conduct magnetic field, so that the magnetic field distribution is more concentrated and uniform.

[0023] In the process of power factor correction, the PFC inductor works with other elements in the circuit (such as diodes, capacitors, etc.). The inductor stores and releases energy to regulate the waveform of the current, so that the input current is closer to the sine wave, thereby improving the power factor. When the voltage in the circuit rises, the inductor stores energy to suppress the rapid rise of current; when the voltage decreases, the inductor releases the stored energy to maintain the stability of the current and compensate for the decrease of voltage, so as to reduce the current harmonics and improve the utilization efficiency of electric energy.

[0024] At the same time, the magnetic core plays a magnetic shielding role for the copper winding. The special structure and material properties of the magnetic core make the electromagnetic radiation generated by the winding limited in the magnetic core, reducing the electromagnetic interference (EMI) to the outside world and improving the electromagnetic compatibility of the whole system. The flat structure of the bottom and top of the inductor is conducive to closely fitting with the heat dissipation device, which can timely dissipate the heat generated in the working process of the inductor, ensuring the stability and reliability of the inductor in high power operation state, and avoiding performance degradation or damage due to overheating.

[0025] The above is only the preferred specific implementation of the present application, but the protection scope of the present application is not limited to this. Any skilled person in the art can make equivalent replacement or change according to the technical scheme and the inventive concept of the present application within the technical range disclosed by the present application, which should be covered in the protection scope of the present application.

Claims

1. A PFC inductor of an ultra-thin LLC resonant topology, characterized in that, Comprise: A magnetic core (1) made of ER high-flux alloy material; A winding (2) formed by winding flat wire; A lead (3) formed by molding process to form SMT mounting pin.

2. The ultra-thin PFC inductor of LLC resonant topology according to claim 1, wherein: The magnetic core (1) is used to shield the winding (2).

3. The ultra-thin LLC resonant topology PFC inductor of claim 1, wherein: The bottom and top of the inductor are flat structures.

4. The ultra-thin PFC inductor of LLC resonant topology of claim 1, wherein: The inductor is suitable for PFC power range of 500W-6KW.

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