Novel magnetic integrated inductor

Abstract

The utility model discloses a novel magnetic integrated inductor which is provided with at least three magnet yokes arranged in sequence, coil windings sleeved on the magnet yokes, a first side column used for installing two adjacent magnet yokes and a second side column parallel to the first side column. The first coil on the upper magnetic core column and the second coil on the lower magnetic core column can share one winding mold, the mold types are reduced, the leading-out ends on the same side of the first coil and the second coil are directly connected in parallel, the process difficulty of series winding of the coils is reduced, the two coils are connected in parallel to share current, and the cost is reduced. The current of a single coil is only half of the total current, so that the coil can be wound by adopting a wire rod with a section area smaller than half, the required turning radius is small when the coil is wound, the size of the coil is favorably reduced, the volume of the inductor is further reduced, and the inductor is suitable for a medium-power and high-power converter.

Description

Technical Field

[0001] This utility model belongs to the field of power electronics technology, and in particular relates to a novel magnetic integrated inductor. Background Technology

[0002] Currently, converter products such as PWM rectifiers, photovoltaic inverters, and new energy storage converters typically require filter inductors to filter out harmonics. While existing solutions using single-phase filter inductors can adapt to unbalanced power grids, the large number of inductors required for each phase leads to a large overall size and high cost, failing to meet the industry's demand for smaller, lower-cost, and lightweight designs. To address this, three-phase three-limb filter inductors, single-phase filter inductors, or improved magnetic integrated inductors are typically used. For example, patent application number 202321198999.6 discloses a magnetic core structure and a magnetic integrated inductor. Figure 1 As shown, the magnetic core structure and the magnetic integrated inductor require at least three parallel magnetic yokes arranged sequentially, with each pair of yokes connected by at least two central pillars to form a layer, and an inductor coil mounted on each central pillar; in addition, it is specified that the relative permeability of the magnetic yokes must be greater than the relative permeability of the central pillars.

[0003] Although the aforementioned improved magnetic integrated inductor can effectively address the shortcomings of three-phase three-limb inductors and single-phase inductors, the existing magnetic integrated inductor windings are constructed by winding on one magnetic core column and then connecting them to another magnetic core column. Consequently, the two coils on the two magnetic core columns are connected in series, which makes the coil manufacturing process difficult. In particular, for high-power inductors, the large cross-sectional area and thicker coils make the coil winding process even more challenging, thus affecting the inductor's production efficiency and hindering mass production. Utility Model Content

[0004] To address the aforementioned problems, this invention provides a novel magnetic integrated inductor that can adapt to unbalanced power grid conditions and solve the problems of high cost and large size associated with using single-phase filter inductors.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This utility model provides a novel magnetic integrated inductor, comprising at least three magnetic yokes arranged in sequence, a coil winding sleeved on each of the magnetic yokes, a first side post for mounting two adjacent magnetic yokes, and a second side post arranged parallel to the first side post;

[0007] The magnetic yoke includes an upper magnetic core column and a lower magnetic core column arranged in parallel. The coil winding includes a first coil wound on the upper magnetic core column and a second coil wound on the lower magnetic core column. The lead-out ends of the first coil and the second coil are connected in parallel on the same side. One end of the upper magnetic core column and one end of the lower magnetic core column are perpendicularly connected to the first side column. The other end of the upper magnetic core column and the other end of the lower magnetic core column are perpendicularly connected to the second side column.

[0008] As a preferred embodiment of the above technical solution, when the number of the first side post and the second side post are both two, the input current at the lead end of the coil winding forms a magnetic flux path for differential mode current or a magnetic flux path for zero-sequence current.

[0009] As a preferred embodiment of the above technical solution, the upper magnetic core column includes at least two detachably connected first magnetic cores.

[0010] As a preferred embodiment of the above technical solution, the lower magnetic core column includes at least two detachably connected second magnetic cores.

[0011] As a preferred embodiment of the above technical solution, the first side post includes at least two detachably connected third magnetic cores.

[0012] As a preferred embodiment of the above technical solution, the second side post includes at least two detachably connected fourth magnetic cores.

[0013] As a preferred embodiment of the above technical solution, at least one first notch is provided on one side of the first side post and the second side post.

[0014] As a preferred embodiment of the above technical solution, at least one second notch is provided on one side of the first side post and the second side post.

[0015] As a preferred embodiment of the above technical solution, the upper magnetic core post and the lower magnetic core post are circular or elliptical in shape.

[0016] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0017] By setting at least three magnetic yokes arranged in sequence, coil windings fitted on each magnetic yoke, a first side post for mounting two adjacent magnetic yokes, and a second side post arranged parallel to the first side post, the first coil on the upper magnetic core post and the second coil on the lower magnetic core post can share a winding mold, reducing the types of molds. The leads on the same side of the first and second coils are directly connected in parallel, reducing the difficulty of series winding of coils. The two coils share the current in parallel, and the current of a single coil is only half of the total current. Therefore, wire with a cross-sectional area of ​​half that can be used to wind the coil. As a result, the bending radius required when winding the coil is small, which is beneficial to reduce the size of the coil and thus the volume of the inductor, making it suitable for medium and high power converters. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of a magnetic core in the prior art;

[0019] Figure 2 This is a schematic diagram of the structure of the novel magnetic integrated inductor proposed in this utility model;

[0020] Figure 3 This is a schematic diagram of the magnetic flux path of the differential mode current proposed in this utility model.

[0021] Figure 4 This is a schematic diagram of the magnetic flux path for the zero-sequence current proposed in this utility model.

[0022] Figure 5 This is a schematic diagram of the upper magnetic core column proposed in this utility model;

[0023] Figure 6 This is a schematic diagram of the lower magnetic core column proposed in this utility model;

[0024] Figure 7 This is a schematic diagram of the structure of the first and second side pillars proposed in this utility model;

[0025] Figure 8 This is another structural schematic diagram of the novel magnetic integrated inductor proposed in this utility model;

[0026] Figure 9 This is a schematic diagram of the structure of the two-phase magnetic integrated inductor proposed in this utility model;

[0027] Figure 10 This is a schematic diagram of the structure of the N-phase magnetic integrated inductor proposed in this utility model;

[0028] Figure 11 This is a schematic diagram of the structure of the first notch proposed in this utility model;

[0029] Figure 12 This is a schematic diagram of the structure of the second notch proposed in this utility model;

[0030] Figure 13 This is another structural schematic diagram of the second notch proposed in this utility model;

[0031] Figure 14 This is a schematic diagram of the circular upper and lower magnetic core columns proposed in this utility model.

[0032] The symbols for the main components are explained below:

[0033] 10-Magnetic yoke; 11-Upper magnetic core post; 12-Lower magnetic core post; 20-Coil winding; 21-First coil; 22-Second coil; 30-First side post; 40-Second side post; 41-First magnetic core; 42-Second magnetic core; 43-Third magnetic core; 44-Fourth magnetic core; 45-First notch; 46-Second notch; 110-First magnetic yoke; 120-Second magnetic yoke; 130-Third magnetic yoke; 140-Fourth magnetic yoke; 300-Coil. Detailed Implementation

[0034] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0035] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", 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.

[0036] See Figure 2 This utility model provides a novel magnetic integrated inductor, including at least three magnetic yokes 10 arranged in sequence, a coil winding 20 sleeved on each of the magnetic yokes 10, a first side post 30 for mounting two adjacent magnetic yokes 10, and a second side post 40 arranged parallel to the first side post 30.

[0037] The magnetic yoke 10 includes an upper magnetic core column 11 and a lower magnetic core column 12 arranged in parallel. The coil winding 20 includes a first coil 21 wound on the upper magnetic core column 11 and a second coil 22 wound on the lower magnetic core column 12. The lead-out end of the first coil 21 and the lead-out end of the second coil 22 are connected in parallel on the same side. One end of the upper magnetic core column and one end of the lower magnetic core column are both perpendicularly connected to the first side column 30. The other end of the upper magnetic core column 11 and the other end of the lower magnetic core column 12 are both perpendicularly connected to the second side column 40.

[0038] In this embodiment, when the number of the first side post 30 and the second side post 40 are both two, the input current at the lead end of the coil winding 20 forms a magnetic flux path for differential mode current or a magnetic flux path for zero-sequence current. The upper magnetic core post 11 includes at least two detachably connected first magnetic cores 41 (e.g., Figure 5(as shown); the lower magnetic core post 12 includes at least two detachably connected second magnetic cores 42 (as shown). Figure 6 (as shown); the first side post 30 includes at least two detachably connected third magnetic cores 43 (as shown). Figure 7 (as shown); the second side post 40 includes at least two detachably connected fourth magnetic cores 44 (as shown). Figure 8 (as shown); at least one first notch 45 is provided on one side of the first side post 30 and the second side post 40 (as shown). Figure 11 (as shown); at least one second notch 46 is provided on one side of the first side post 30 and the second side post 40 (as shown). Figure 12 (as shown); the upper magnetic core post 11 and the lower magnetic core post 12 are circular in shape (as shown). Figure 14 (as shown) or elliptical in shape.

[0039] It should be noted that, as Figure 1 As shown, the three magnetic yokes 10 are distributed in an upper, middle, and lower configuration. Taking four magnetic yokes 10 as an example, they are the first magnetic yoke 110, the second magnetic yoke 120, the third magnetic yoke 130, and the fourth magnetic yoke 140. The four magnetic yokes 10 have a three-layer structure: the first magnetic yoke 110 and the second magnetic yoke 120 form the first layer, the second magnetic yoke 120 and the third magnetic yoke 130 form the second layer, and the third magnetic yoke 130 and the fourth magnetic yoke 140 form the third layer. Each layer includes two central pillars.

[0040] When there are two yokes 10, a two-phase magnetic integrated inductor (which can be simply referred to as a two-phase inductor) is formed. The corresponding coil windings 20 are denoted as phase A and phase B. The leads of phase A coil winding and phase B coil winding are connected in parallel. Preferably, the yokes, coils, or side post structures of phase A and phase B are the same. Figure 9 As shown. When the number of yokes 10 is three, a three-phase magnetic integrated inductor is formed. The corresponding coil windings 20 are denoted as phase A, phase B, and phase C, including the parallel leads of the phase A coil winding, the parallel leads of the phase B coil winding, and the parallel leads of the phase C coil winding, as shown. Figure 6 As shown. In other words, the left lead of the upper magnetic core coil (first coil 21) is connected in parallel with the left lead of the lower magnetic core coil (second coil 22), and the right lead of the upper magnetic core coil is connected in parallel with the right lead of the lower magnetic core coil.

[0041] The advantages of parallel coil connection are: (1) the coil of the upper magnetic core column 11 and the coil of the lower magnetic core column 12 can share the same winding mold, reducing the types of molds; (2) the leads on the same side of the coil can be directly connected in parallel, which is simple and saves the process difficulty of coil series winding; (3) since the two coils are connected in parallel to share the current, the current of a single coil is only half of the total current, and a wire with a cross-sectional area of ​​half that can be used to wind the coil. The bending radius required when winding the coil is small, which is conducive to reducing the size of the coil and thus reducing the volume of the inductor.

[0042] Specifically, by winding the coil around the upper magnetic core post 11 and the lower magnetic core post 12, and by providing four side posts, a magnetic flux path for the differential mode current (such as...) is provided. Figure 3 As shown), it also provides the magnetic flux path for zero-sequence current (e.g. Figure 4 As shown in the diagram, this design meets the requirements for applications in unbalanced power grids containing zero-sequence current. Phase A (inductor) and Phase B (inductor) share the intermediate side column core Z2 (first side column 30), and Phase B (inductor) and Phase C (inductor) share the intermediate side column core Z3 (second side column 40), thereby reducing the number of side column cores, decreasing size, and lowering cost. The direction of the zero-sequence magnetic flux path of Phase B in the intermediate side column Z2 is opposite to the direction of the zero-sequence magnetic flux of Phase A, resulting in flux cancellation; the direction of the zero-sequence magnetic flux of Phase B in the intermediate side column Z3 is opposite to the direction of the zero-sequence magnetic flux of Phase C, also resulting in flux cancellation, thereby reducing core losses and improving efficiency.

[0043] Specifically, the upper magnetic core post 11, the lower magnetic core post 12, and the side posts (first side post 30 or second side post 40) can all use magnetic cores of the same material or different materials, depending on the specific product requirements, but all are within the scope of this utility model. The winding direction of the B-phase coil can be the same as or opposite to the winding direction of the A-phase and C-phase coils (e.g., ...). Figure 2 As shown, the appropriate option can be selected based on the specific product, but all are within the scope of this utility model. The specific choice can be made according to the actual situation.

[0044] The upper core post 11 can be a single, integral core, or it can be composed of two or more cores joined together (e.g., Figure 5 Similarly, the lower core post 12 can also be composed of two or more cores joined together (e.g., Figure 6 The side post can also be made of two or more magnetic cores joined together (e.g., Figure 7 The side posts, upper core post 11, and lower core post 12 can all be composed of two or more cores joined together (e.g., Figure 8 Furthermore, the upper magnetic core post 11 and the lower magnetic core post 12 can be either elliptical or circular. Figure 14 ).

[0045] It should be understood that by setting at least three magnetic yokes 10 arranged in sequence, coil windings 20 sleeved on each magnetic yoke 10, first side posts 30 for mounting two adjacent magnetic yokes 10, and second side posts 40 arranged parallel to the first side posts 30, the first coil 21 on the upper magnetic core post 11 and the second coil 22 on the lower magnetic core post 12 can share a winding mold, reducing the types of molds. The lead-out ends of the first coil 21 and the second coil 22 on the same side are directly connected in parallel, reducing the difficulty of the series winding process. The two coils are connected in parallel to share the current, and the current of a single coil is only half of the total current. Therefore, wire with a cross-sectional area half that of the coil can be used to wind the coil. As a result, the bending radius required when winding the coil is small, which is beneficial to reduce the size of the coil and thus the volume of the inductor. This is suitable for medium and high power converters, such as photovoltaic systems, electrochemical energy storage systems, and other medium and high power converters.

[0046] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A novel magnetic integrated inductor, characterized in that, It includes at least three magnetic yokes arranged in sequence, a coil winding sleeved on each of the magnetic yokes, a first side post for mounting two adjacent magnetic yokes, and a second side post arranged parallel to the first side post; The magnetic yoke includes an upper magnetic core column and a lower magnetic core column arranged in parallel. The coil winding includes a first coil wound on the upper magnetic core column and a second coil wound on the lower magnetic core column. The lead-out ends of the first coil and the second coil are connected in parallel on the same side. One end of the upper magnetic core column and one end of the lower magnetic core column are perpendicularly connected to the first side column. The other end of the upper magnetic core column and the other end of the lower magnetic core column are perpendicularly connected to the second side column.

2. The novel magnetic integrated inductor according to claim 1, characterized in that, When the number of the first side post and the number of the second side post are both two, the input current at the lead end of the coil winding forms a magnetic flux path for differential mode current or a magnetic flux path for zero sequence current.

3. The novel magnetic integrated inductor according to claim 2, characterized in that, The upper magnetic core column includes at least two detachably connected first magnetic cores.

4. The novel magnetic integrated inductor according to claim 2, characterized in that, The lower magnetic core column includes at least two detachably connected second magnetic cores.

5. The novel magnetic integrated inductor according to claim 2, characterized in that, The first side post includes at least two detachably connected third magnetic cores.

6. The novel magnetic integrated inductor according to claim 2, characterized in that, The second side post includes at least two detachably connected fourth magnetic cores.

7. The novel magnetic integrated inductor according to claim 1, characterized in that, At least one first notch is provided on one side of the first side post and the second side post.

8. The novel magnetic integrated inductor according to claim 1, characterized in that, At least one second notch is provided on each of the two sides of the first side post and the second side post.

9. The novel magnetic integrated inductor according to claim 1, characterized in that, The upper magnetic core post and the lower magnetic core post are circular or elliptical in shape.

Images