Magnetic circuit-integrated PFC (Power Factor Correction) inductor

Abstract

The utility model discloses an integrated magnetic circuit PFC inductor which comprises a magnetic core combination structure and a coil assembly, the magnetic core combination structure comprises at least two magnetic parts made of different magnetic materials, the magnetic parts are combined to form the magnetic core combination structure, and a wrapping post is arranged on the magnetic core combination structure; the coil assembly is sleeved on the wrapping post. According to the magnetic circuit integrated PFC inductor, the magnetic core combination structure and the coil assembly are arranged, and the magnetic core combination structure is formed by combining at least two magnetic pieces made of different magnetic materials, that is, two or more than two magnetic materials are integrated into the same magnetic circuit, so that magnetoelectric conversion is improved, and meanwhile, the electrical performance of the inductor is more convenient to adjust.

Description

TECHNICAL FIELD

[0001] The utility model relates to magnetic component technical field especially relates to a kind of magnetic circuit PFC inductance. BACKGROUND

[0002] PFC inductance is a kind of inductor for composing PFC (Power Factor Correction) circuit. The main function of PFC inductance is to smooth the current in the circuit, reduce high harmonic, reduce invalid power loss, and improve the power factor of power supply, so as to improve the stability and efficiency of the circuit.

[0003] But the existing PFC inductance is all made of single magnetic material to make magnetic core, and the magnetic core is all integrated structure, please refer to Figure 1 The structure leads to the adjustment of the electrical performance of inductor is more difficult. UTILITY MODEL CONTENT

[0004] The utility model aims at overcoming the insufficient in prior art, provide a kind of magnetic circuit PFC inductance, to be able to adjust the electrical performance of inductance conveniently.

[0005] The utility model aims at overcoming the insufficient in prior art, provide a kind of magnetic circuit PFC inductance, to be able to adjust the electrical performance of inductance conveniently.

[0006] A kind of magnetic circuit PFC inductance, comprising: magnetic core combination structure and coil assembly, the magnetic core combination structure includes at least two different magnetic material magnetic pieces, each the magnetic piece combination forms the magnetic core combination structure, and winding post is provided on the magnetic core combination structure;The coil assembly is set on the winding post.

[0007] In one embodiment, the magnetic core combination structure includes a first magnetic piece and a second magnetic piece, the first magnetic piece and the second magnetic piece combine to form the magnetic core combination structure, and a winding post is provided on the magnetic core combination structure.

[0008] In one embodiment, the first magnetic piece includes a first winding post and two magnetic core limiting blocks, and the second magnetic piece includes a second winding post, one end of the first winding post is connected with one of the magnetic core limiting blocks, one end of the second winding post is connected with the other end of the first winding post, and the other end of the second winding post is connected with the other magnetic core limiting block, and the first winding post and the second winding post combine to form the winding post.

[0009] In one embodiment, the first winding post is provided with two, and the second winding post is provided with two, any one of the first winding post and any one of the second winding post combines to form the winding post, and the winding post is arranged between the two magnetic core limiting blocks.

[0010] In one of the embodiments, the first magnetic member is a metal powder core, and the second magnetic member is a ferrite magnetic column.

[0011] In one of the embodiments, the coil assembly comprises a first coil and a second coil, which are respectively sleeved on the two winding columns.

[0012] In one of the embodiments, the first magnetic member and the second magnetic member are detachably combined.

[0013] In one of the embodiments, a base is further included, and the magnetic core combination structure and the coil assembly are respectively arranged on the base.

[0014] In one of the embodiments, the base is a heat dissipation base.

[0015] Compared with the prior art, the utility model has at least the following advantages:

[0016] The magnetic circuit PFC inductor of the utility model is combined by the magnetic core combination structure and the coil assembly, and the magnetic core combination structure is combined by at least two magnetic members of different magnetic materials, that is, two or more magnetic materials are combined in the same magnetic circuit, the magnetic-electric conversion is improved, and the electric performance of the inductor can be adjusted more conveniently compared with the existing single magnetic material integrated magnetic core structure. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical scheme of the embodiments of the utility model, the drawings needed to be used in the embodiments will be briefly introduced as follows.

[0018] Figure 1 It is a structural schematic view of an existing magnetic core structure;

[0019] Figure 2 It is a structural schematic view of the magnetic circuit PFC inductor in one of the embodiments of the utility model;

[0020] Figure 3 It is Figure 2 It is a structural schematic view of the magnetic core combination structure of the magnetic circuit PFC inductor in the embodiment of the utility model;

[0021] Figure 4 It is Figure 3 It is an exploded structural schematic view of the magnetic core combination structure in the embodiment of the utility model;

[0022] Figure 5 It is Figure 2 It is a structural schematic view of the base of the magnetic circuit PFC inductor in the embodiment of the utility model;

[0023] Figure 6 It is Figure 2Structure diagram of another embodiment of the base of the magnetic circuit PFC inductor; DETAILED DESCRIPTION

[0024] In order to facilitate the understanding of the present application, the present application will be described more fully below with reference to the accompanying drawings.

[0025] Please refer to Figure 2 , Figure 3 and Figure 4 , a magnetic circuit PFC inductor, comprising: a magnetic core combination structure 100 and a coil assembly 200, the magnetic core combination structure 100 comprising at least two magnetic pieces of different magnetic materials, each magnetic piece being combined to form the magnetic core combination structure 100, and the magnetic core combination structure 100 being provided with a winding column; the coil assembly 200 being sleeved on the winding column.

[0026] It should be noted that the magnetic core combination structure 100 is combined by at least two magnetic pieces of different magnetic materials, that is, two or more magnetic materials are collected into the same magnetic circuit, which improves the magnetic-electric conversion and is more convenient for adjusting the electrical performance of the inductor. In addition, compared with a traditional single-material magnetic core of the same size, under the condition of ensuring the same electrical performance, the magnetic circuit PFC inductor of the present application can reduce the number of winding coils of the coil assembly 200 by adjusting the electrical performance of the magnetic core combination structure 100, thereby reducing the volume of the coil and realizing miniaturization design, reducing the cost to a certain extent, and further reducing the direct current resistance.

[0027] In an embodiment, the magnetic core combination structure 100 comprises a first magnetic piece 110 and a second magnetic piece 120, the first magnetic piece 110 and the second magnetic piece 120 being combined to form a magnetic core combination structure, and the magnetic core combination structure 100 being provided with a winding column. In this way, by collecting two magnetic materials in the same magnetic circuit, the magnetic-electric conversion can be improved, and under the condition of ensuring the electrical performance, the volume of the coil can be reduced by changing the number of winding coils of the coil assembly 200, thereby realizing the miniaturization design of the inductor.

[0028] Specifically, the first magnetic piece 110 comprises a first winding column 111 and two magnetic core limiting blocks 112, and the second magnetic piece 120 comprises a second winding column 121, one end of the first winding column 111 being connected with one of the magnetic core limiting blocks 112, one end of the second winding column 121 being connected with the other end of the first winding column 111, and the other end of the second winding column 121 being connected with the other magnetic core limiting block 112, the first winding column 111 and the second winding column 121 being combined to form the winding column.

[0029] It needs to be explained that by splitting the winding post into the first winding post 111 and the second winding post 121 of different magnetic materials, the two kinds of magnetic materials are collected in the same magnetic circuit to improve the magnetic-electric conversion, thereby facilitating the adjustment of the electrical performance. In the embodiment, the first magnetic member 110 and the second magnetic member 120 can be split and combined, for example, the connection can be formed by the magnetic property of the magnetic member. In this way, not only the electrical performance of the inductor can be adjusted, but also the winding assembly of the coil can be facilitated. For reference Figure 1 The magnetic core structure is a conventional magnetic core structure, and the magnetic core of the conventional inductor is of a single material and is of a one-piece structure, for example Figure 1 The magnetic core is of a mouth-shaped structure, and the winding operation of the coil is generally not facilitated due to the fact that the magnetic core is a whole, thereby increasing the winding difficulty of the coil. Meanwhile, the magnetic core is a whole, and the adjustment of the electrical performance is more difficult. Compared with the conventional mouth-shaped magnetic core, the magnetic circuit PFC inductor of the utility model is divided into the block-shaped magnetic core combination structure 100, and the coil assembly 200 is only needed to be placed on the winding post of the magnetic core combination structure 100, thereby facilitating the winding and improving the production efficiency. Meanwhile, compared with the magnetic core structure of a single material, the magnetic core combination structure 100 of the utility model can be used in cooperation with several materials, thereby facilitating the adjustment of the electrical performance.

[0030] Further, the first winding post 111 is provided with two, and the second winding post 121 is provided with two, and the winding post is formed by combining any one of the first winding post 111 and any one of the second winding post 121, and the winding post is arranged between the two magnetic core limiting blocks 112. That is, the winding post on the magnetic core combination structure 100 is provided with two, and correspondingly, in the embodiment, the coil assembly 200 includes the first coil 210 and the second coil 220, and the first coil 210 and the second coil 220 are respectively sleeved on the two winding posts. Since the magnetic core combination structure 100 is split, the assembly of the first coil 210 and the second coil 220 is facilitated, the winding difficulty of the coil is reduced, and the production efficiency is improved.

[0031] It also needs to be explained that since the two first winding posts 111, the two second winding posts 121 and the two magnetic core limiting blocks 112 are block structures that can be split and connected, compared with the conventional one-piece magnetic core structure of a single material, the following three outstanding advantages are obtained:

[0032] 1. The magnetic core combination structure 100 combined by the block-shaped magnetic materials is more convenient for the winding of the coil, reduces the winding difficulty and improves the efficiency.

[0033] 2. The magnetic core assembly structure 100, composed of multiple different block magnetic materials, facilitates the adjustment of electrical performance. For example, it makes it easier to adjust the air gap of the magnetic core assembly structure. By adjusting the air gap, the inductance value can be effectively controlled, while improving the linearity and temperature stability of the PFC inductor in the collector circuit. This increases the flexibility of the magnetic core assembly structure 100. Furthermore, the electrical performance can also be adjusted by changing the selection of magnetic materials, such as changing the second winding post 121.

[0034] 3. Compared with traditional magnetic core structures of the same size, the number of winding coils can be reduced by adjusting the magnetic core assembly structure 100. Under the same electrical performance, the volume of the coil can be reduced by reducing the number of coil turns, thereby achieving miniaturization design, reducing costs, and further reducing DC resistance.

[0035] Preferably, the first magnetic element 110 is a metal powder core, and the second magnetic element 120 is a ferrite core. The metal powder core has high permeability, while the ferrite core also possesses good magnetic conductivity. The magnetic core assembly structure 100 formed by combining the metal powder core and the ferrite core can further improve the permeability of the PFC inductor, thereby enhancing the inductance and efficiency of the PFC inductor. Furthermore, designing the first magnetic element 110 and the second magnetic element 120 as multiple block structures and combining them to form the magnetic core assembly structure 100 facilitates the adjustment of the electrical performance of the PFC inductor by changing and adjusting the first and second magnetic elements 120. It also facilitates the assembly of the magnetic core assembly structure 100, thereby reducing the requirements for coil winding and improving winding efficiency.

[0036] Please see Figure 5 As shown, in one embodiment, the magnetic circuit PFC inductor further includes a base 300, with the magnetic core assembly structure 100 and the coil assembly 200 respectively disposed on the base 300. The connecting end of the coil assembly 200 passes through the base 300 to facilitate connection with other components.

[0037] In this embodiment, the base 300 is a heat dissipation base 300, which improves the heat dissipation effect of the PFC inductor in the magnetic circuit. For example, a heat dissipation base 300 made of metal can be used to ensure heat dissipation, such as copper. For applications with high insulation requirements, an insulating and thermally insulating adhesive layer, such as thermally conductive silicone or thermally conductive potting compound, can be wrapped around the metal heat dissipation base 300.

[0038] In order to improve the limit of the coil assembly 200, reduce the displacement risk of the magnetic core combination structure 100 and the coil assembly 200, increase the contact of the coil assembly 200 and the base 300, and further improve the heat dissipation effect, in the embodiment, the base 300 is provided with a heat dissipation limiting groove 310 and a limiting boss 320. The limiting boss 320 is arranged on one side of the heat dissipation limiting groove 310. The bottom of the coil assembly 200 is located in the heat dissipation limiting groove 310. The limiting boss 320 is located on the side of the coil assembly 200. Through the cooperation of the heat dissipation limiting groove 310 and the limiting boss 320, the limiting effect of the coil assembly 200 is achieved. At the same time, through the heat dissipation limiting groove 310, the contact area of the coil assembly 200 and the base 300 can be increased, and the heat dissipation efficiency is improved. In the embodiment, in order to match two coils, the heat dissipation limiting groove 310 is provided with two heat dissipation limiting grooves 310, and the limiting boss 320 is also provided with two limiting bosses 320. The two limiting bosses 320 are located on the two sides of the two heat dissipation limiting grooves 310.

[0039] Since the base 300 is a flat structure, when the magnetic path PFC inductor is installed on the corresponding electronic module, the gap between the bottom surface of the base 300 and the electronic module is small, the ventilation effect is poor, the heat dissipation effect of the base 300 is poor, and most of the heat is conducted to the corresponding electronic module, reducing the performance of the electronic module. Therefore, in the embodiment, a heat insulation layer is arranged on the side of the base 300 away from the coil assembly 200 and the magnetic core combination structure 100. The heat insulation layer can be made of epoxy resin, polyurethane foam, aerogel felt and other heat insulation materials, so as to block the heat conduction from the base 300 to the corresponding electronic module. At the same time, in order to further improve the heat dissipation effect, please refer to Figure 6 As shown in the figure, the base 300 is provided with a heat dissipation reinforcing structure 310. The heat dissipation reinforcing structure 310 includes a heat dissipation extension part 311 and a heat dissipation reinforcing part 312. One end of the heat dissipation extension part 311 is connected with the base 300. The other end of the heat dissipation extension part 311 extends away from the base 300. The heat dissipation reinforcing part 312 is arranged on the heat dissipation extension part 311. In this way, through the cooperation of the heat dissipation reinforcing structure 310 and the heat insulation layer, the heat dissipation area can be greatly increased, and the heat dissipation effect is improved. For example, the heat dissipation reinforcing part 312 is a copper heat dissipation fin.

[0040] A magnetic core combination method applied to the magnetic path PFC inductor, comprising:

[0041] Step S01: selecting a plurality of magnetic materials with different Ui (initial magnetic permeability) values; for example, Fe-Si-26, Fe-Si-40, Fe-Si-60, Fe-Si-75 materials; ferrite 95, ferrite 96, ferrite 91, ferrite 28 materials, etc.

[0042] Step S02: test the inductance of the magnetic material with different Ui value under no bias current condition;

[0043] Step S03: according to the inductance specification of the required inductor, combine the magnetic material with matched inductance under no bias current condition to obtain the magnetic core combination structure 100;

[0044] Step S04: test the inductance of the magnetic core combination structure 100 under bias current condition;

[0045] Step S05: according to the inductance specification of the required inductor, adjust the size and air gap of the magnetic core combination structure so that the magnetic core combination structure reaches the inductance of the required inductor under bias current condition. In this way, the required magnetic circuit PFC inductor can be combined and matched. Since the inductance of different magnetic materials decreases at different rates under bias current condition, the magnetic core combination structure needs to be adjusted to reach the required inductance specification. The traditional single material integrated magnetic core cannot be adjusted in terms of electrical performance.

[0046] The above embodiments only express several implementation manners of the present application, and the description is relatively specific and detailed, but it should not be understood as a limitation on the scope of the present application. It should be pointed out that for ordinary skilled persons in the art, some modifications and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the appended claims.

Claims

1. A magnetic circuit PFC inductor, characterized in that, include: A magnetic core assembly structure, comprising at least two magnetic components of different magnetic materials, wherein the magnetic components are combined to form the magnetic core assembly structure, and a winding post is disposed on the magnetic core assembly structure; and A coil assembly, wherein the coil assembly is sleeved on the winding post.

2. The magnetic circuit PFC inductor according to claim 1, characterized in that, The magnetic core assembly structure includes a first magnetic element and a second magnetic element, which are combined to form the magnetic core assembly structure. A winding post is provided on the magnetic core assembly structure.

3. The magnetic circuit PFC inductor according to claim 2, characterized in that, The first magnetic component includes a first winding post and two magnetic core limiting blocks, and the second magnetic component includes a second winding post. One end of the first winding post is connected to one of the magnetic core limiting blocks, one end of the second winding post is connected to the other end of the first winding post, and the other end of the second winding post is connected to the other magnetic core limiting block. The first winding post and the second winding post are combined to form the winding post.

4. The magnetic circuit PFC inductor according to claim 3, characterized in that, Two first winding posts are provided, and two second winding posts are provided. Any one of the first winding posts and any one of the second winding posts are combined to form the winding post, and the winding post is disposed between the two magnetic core limiting blocks.

5. The magnetic circuit PFC inductor according to any one of claims 2-4, characterized in that, The first magnetic component is a metal powder core, and the second magnetic component is a ferrite magnetic column.

6. The magnetic circuit PFC inductor according to claim 4, characterized in that, The coil assembly includes a first coil and a second coil, which are respectively sleeved on the two winding posts.

7. The magnetically collected circuit PFC inductor according to any one of claims 2-4, characterized in that, The first magnetic component and the second magnetic component can be detached and combined.

8. The magnetic circuit PFC inductor according to any one of claims 2-4, characterized in that, It also includes a base, on which the magnetic core assembly and the coil assembly are respectively disposed.

9. The magnetic circuit PFC inductor according to claim 8, characterized in that, The base is a heat dissipation base.

Images