Inductor structure and power factor corrector comprising same

Abstract

The utility model provides an inductor structure and a power factor corrector comprising the same, the inductor structure comprises a magnetic core assembly, and the magnetic core assembly comprises a magnetic core male component and a magnetic core female component which are paired with each other; the framework assembly comprises a framework male component and a framework female component which are matched with each other; the flat wire coil is pre-wound, and is wound into a ring shape; the framework male component is mounted to one of the magnetic core male component and the magnetic core female component, and the framework female component is mounted to the other one of the magnetic core male component and the magnetic core female component; when the framework male component and the framework female component are assembled together, the framework assembly penetrates through the annular flat wire coil. Through the configuration, the operation of winding the flat wire coil in advance before the framework assembly is assembled is realized, and the prefabrication degree of each assembly of the inductor structure is improved, so that the overall manufacturing efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of electronic components technology, and more particularly to an inductor structure and a power factor correction (PFC) device incorporating the same. Background Technology

[0002] Current power electronic equipment (PEE) demands increasingly stringent performance requirements for components. Furthermore, societal development necessitates greater integration and miniaturization of PFCs. These demands drive component development while simultaneously posing challenges to the high-frequency transformer / inductor manufacturing industry. Particularly, for PFCs used in high-current applications, thicker wire diameters are required to handle the high current. Additionally, PFCs face specific size and safety regulations. Existing inductor structures using toroidal cores and parallel bi-wire windings present limitations. Firstly, automated winding processes cannot improve production efficiency. Secondly, the space utilization of parallel bi-wire windings fails to meet the overall dimensional requirements of PFC structures in PEE. Generally, when circular cross-section wires are wound on toroidal cores, gaps inevitably exist, with a fill factor expected to be only 40%-50%, resulting in relatively low space utilization.

[0003] Chinese utility model patent CN210896933U discloses an inductor comprising a base, a magnetic core assembly, a frame, and a coil, wherein the coil is formed by winding round wire, flat wire, or stranded wire. However, the frame has flanges at both ends, which prevents the pre-winding of the coil before assembly and then fitting it onto the outer circumference of the frame, thus reducing the prefabrication level of the inductor's components. Chinese invention patent application CN118263003A discloses an integrated magnetic element comprising a magnetic core, a main coil, and a magnetic coil, wherein the coil is wound using an automated flat wire vertical winding method. However, the coil is still wound on the center / side posts instead of being pre-wound and then fitted onto the outer circumference of the center / side posts, similarly reducing the prefabrication level of the integrated magnetic element's components. Utility Model Content

[0004] This application provides an inductor structure and a power factor corrector (PFC) including the same, to address the shortcomings of existing technologies where coils pre-wound from flat wire are inconvenient to assemble. This invention realizes an inductor structure and PFC that has a high fill factor and is suitable for coils pre-wound using automated winding processes.

[0005] According to a first aspect of this application, this application provides an inductor structure, comprising:

[0006] A magnetic core assembly, comprising a male core component and a female core component that are paired with each other;

[0007] A skeleton assembly, comprising male skeleton members and female skeleton members that are paired with each other;

[0008] Flat wire coils are pre-wound and wound into a loop;

[0009] The male skeleton component is installed to one of the male core component and the female core component, and the female skeleton component is installed to the other of the male core component and the female core component; when the male skeleton component and the female skeleton component are assembled together, the skeleton assembly passes through the toroidal flat wire coil.

[0010] According to an inductor structure provided in this application, it also includes a base, and a magnetic core assembly, a frame assembly, and a flat wire coil are all arranged on the base.

[0011] According to an inductor structure provided in this application, a flat wire coil has a first connecting end and a second connecting end; the base includes a first through slot and a second through slot, the first through slot allowing the first connecting end to pass through, and the second through slot allowing the second connecting end to pass through.

[0012] According to an inductor structure provided in this application, the flat wire coil adopts a disc-shaped multilayer coil, wherein the annular flat wire coil is axially arranged into two discs, and each disc has the same number of layers.

[0013] According to an inductor structure provided in this application, the flat wire coil is wound using an automated winding process.

[0014] According to an inductor structure provided in this application, the male core component includes a linearly extending magnetic core, and the female core component includes a receiving portion for receiving the end section of the magnetic core.

[0015] According to an inductor structure provided in this application, the male skeleton component includes a linearly extending first hollow sleeve, and the female skeleton component includes a linearly extending second hollow sleeve, wherein the first hollow sleeve and the second hollow sleeve are detachably connected.

[0016] According to an inductor structure provided in this application, the inner diameters of both the first hollow sleeve and the second hollow sleeve are larger than the diameter of the magnetic core.

[0017] According to an inductor structure provided in this application, the outer diameters of both the first hollow sleeve and the second hollow sleeve are smaller than the inner diameter of the annular flat wire coil.

[0018] According to a second aspect of this application, this application also provides a power factor corrector that includes the inductor structure described in the first aspect of this application.

[0019] The inductor structure and power factor corrector including therein provided in this application, through the combination of a separable magnetic core assembly, a frame assembly, and a flat wire coil through which the two are passed, enables the pre-winding of the flat wire coil before assembling the frame assembly. This allows for the application of automated winding processes to the flat wire coil and improves the prefabrication of each component of the inductor structure, thereby increasing overall manufacturing efficiency. Furthermore, the flat wire coil provided in this application, by employing a multi-layered, disc-shaped coil arranged in two discs along the axial direction of the flat wire coil, achieves a fill factor of up to 70%-90%, significantly improving the space utilization of the coil compared to the 40%-50% fill factor of existing technologies. Moreover, the inductor structure and power factor corrector including therein provided in this application, by configuring the frame assembly, avoids direct contact between the magnetic core assembly and the flat wire coil, providing a solution to the problems of mutual compression and heat dissipation. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a perspective view of the inductor structure provided in this application in its assembled state.

[0022] Figure 2 yes Figure 1 The exploded view of the inductor structure is shown.

[0023] Figure 3 This is a perspective view of a flat wire coil of the inductor structure provided in this application.

[0024] Figure label:

[0025] 100. Magnetic core assembly; 101. Male magnetic core component; 102. Female magnetic core component; 103. Magnetic core; 200. Skeleton assembly; 201. Male skeleton component; 202. Female skeleton component; 203. First hollow sleeve; 204. Second hollow sleeve; 300. Flat wire coil; 301. First connecting end; 302. Second connecting end; 400. Base; 401. First through slot; 402. Second through slot. Detailed Implementation

[0026] The embodiments of this application will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this application, but should not be used to limit the scope of this application.

[0027] In the description of the embodiments of this application, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application 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. Therefore, they should not be construed as limitations on the embodiments of this application. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0028] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections, wherein a fixed connection can include an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application based on the specific circumstances.

[0029] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0030] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the embodiments of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0031] The following is combined Figures 1 to 3 This application describes the inductor structure and the power factor correction device incorporating it.

[0032] Figure 1 This is a perspective view of the inductor structure provided in this application in its assembled state, and Figure 2 yes Figure 1 An exploded view of the inductor structure is shown. Figure 1-2 As shown, the inductor structure includes a magnetic core assembly 100, a frame assembly 200, and a flat wire coil 300.

[0033] Commercially available coils are generally made using circular cross-section wire. Whether wound around a toroidal or linear magnetic core, gaps inevitably exist between the turns of the circular cross-section wire, resulting in low space utilization. Therefore, this application uses flat cross-section wire to wind the coil, thus obtaining a flat wire coil 300. Figure 3 As shown, before assembling the inductor structure, an automated winding process can be used to pre-wind the flat wire coil 300. Specifically, the flat wire coil 300 is wound into a disc-shaped multilayer coil form, wherein, along the axial direction of the flat wire coil, the flat wire coil 300 is wound into two discs, each disc having the same plurality of layers of flat wire. Moreover, as can be seen from the figure, the flat cross-section conductor crosses between the two discs in the innermost layer of the flat wire coil 300. The above-described coil construction facilitates the pre-winding of the flat wire coil 300 before assembly.

[0034] Back Figure 1-2 The core assembly 100 includes a male core member 101 and a female core member 102 that are paired with each other; the skeleton assembly 200 includes a male skeleton member 201 and a female skeleton member 202 that are paired with each other. Specifically, the male core member 101 includes a core 103 that extends linearly from its body, particularly toward the female core member 102, while the female core member 102 includes a receiving portion (not shown) for receiving the end section of the core 103; the male skeleton member 201 includes a first hollow sleeve 203 that extends linearly from its body, particularly toward the female skeleton member 202, while the female skeleton member 202 includes a second hollow sleeve 204 that extends linearly from its body, particularly toward the male skeleton member 201.

[0035] In the process of assembling the inductor structure, the first operation is to install the male skeleton component 201 to one of the male core component 101 and the female core component 102, for example, the male core component 101; the female skeleton component 202 is installed to the other of the male core component 101 and the female core component 102, for example, the female core component 102.

[0036] Next, the male core component 101 with the skeleton male component 201 installed is connected to the female core component 102 with the skeleton female component 202 installed. The magnetic core 103 of the male core component 101 is received by the receiving part of the female core component 102. Simultaneously, the first hollow sleeve 203 and the second hollow sleeve 204 are detachably connected. For example, at least a section of the second hollow sleeve 204 is fitted onto the outer circumferential surface of the first hollow sleeve 203, or the respective ends of the two hollow sleeves are snap-fitted or inserted relative to each other, or other similar connection methods. Furthermore, the magnetic core 103 passes through the channel defined by the first hollow sleeve 203 and the second hollow sleeve 204, meaning that the inner diameters of both the first hollow sleeve 203 and the second hollow sleeve 204 are larger than the diameter of the magnetic core 103.

[0037] While assembling the magnetic core assembly 100 and the frame assembly 200, the flat wire coil 300 is fitted onto the connected first hollow sleeve 203 and second hollow sleeve 204. In other words, the flat wire coil 300 is indirectly fitted onto the magnetic core 103. For this purpose, the inductor structure is designed such that the outer diameters of both the first hollow sleeve 203 and the second hollow sleeve 204 are smaller than the inner diameter of the annular flat wire coil 300. The flat wire coil 300 being fitted onto the frame assembly 200 offers the following advantages: the winding pressure of the flat wire coil 300 is borne by the frame assembly 200, thus preventing fatigue damage caused by continuous pressure on the magnetic core 103; furthermore, the frame assembly 200 can also be designed to be made of a thermally conductive material to provide heat dissipation for the inductively heated flat wire coil 300 during inductor operation.

[0038] Compared to Chinese utility model patent CN210896933U, in which the skeleton (30) has flanges (32) at both ends, it is impossible to fit the pre-wound coil (40) onto the outer circumference of the skeleton (30). In other words, even if an automated winding process is used to wind the coil (40), it must be done on the skeleton (30). In contrast, the skeleton assembly 200 in this application is a split design, which allows the first hollow sleeve 203 and the second hollow sleeve 204 to pass through the central hole of the flat wire coil 300 during the assembly process. That is, both the split skeleton assembly 200 and the pre-wound flat wire coil 300 have a high degree of prefabrication, thereby improving the overall manufacturing efficiency of the inductor structure.

[0039] Preferably, the inductor structure of this application further includes a base 400, with the core assembly 100, frame assembly 200, and flat wire coil 300 all arranged above the base 400. Specifically, as long as the core assembly 100 is installed above the base 400, and based on the sequential nesting relationship of the core assembly 100, frame assembly 200, and flat wire coil 300, it can be ensured that both the frame assembly 200 and the flat wire coil 300 are above the base 400. Further, the flat wire coil 300 has a first connecting end 301 and a second connecting end 302 extending from the outermost layer of the two coils, respectively; correspondingly, the base 400 includes a first through slot 401 and a second through slot 402, wherein the first through slot 401 allows the first connecting end 301 to pass through, and the second through slot 402 allows the second connecting end 302 to pass through. Based on this, the first connecting end 301 and the second connecting end 302 extending from the base 400 facilitate electrical connection with the positive / negative poles of an external power supply.

[0040] According to another aspect of this application, this application also provides a PFC that includes an inductor structure constructed as described above.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. An inductor structure, characterized in that, include: A magnetic core assembly (100) includes a male magnetic core component (101) and a female magnetic core component (102) that are paired with each other. A skeleton assembly (200) includes a male skeleton component (201) and a female skeleton component (202) that are paired with each other. Flat wire coil (300), the flat wire coil is pre-wound and wound into a ring; The skeleton male component (201) is installed to one of the magnetic core male component (101) and the magnetic core female component (102), and the skeleton female component (202) is installed to the other of the magnetic core male component (101) and the magnetic core female component (102); when the skeleton male component (201) and the skeleton female component (202) are assembled together, the skeleton assembly (200) passes through the annular flat wire coil (300).

2. The inductor structure according to claim 1, characterized in that, It also includes a base (400), on which the magnetic core assembly (100), the skeleton assembly (200) and the flat wire coil (300) are arranged.

3. The inductor structure according to claim 2, characterized in that, The flat wire coil (300) has a first connecting end (301) and a second connecting end (302); the base (400) includes a first through groove (401) and a second through groove (402), the first through groove (401) through which the first connecting end (301) passes, and the second through groove (402) through which the second connecting end (302) passes.

4. The inductor structure according to claim 1, characterized in that, The flat wire coil (300) is a disc-shaped multilayer coil, wherein the annular flat wire coil (300) is axially arranged into two discs, each disc having the same number of layers.

5. The inductor structure according to claim 4, characterized in that, The flat wire coil (300) is wound using an automated winding process.

6. The inductor structure according to claim 1, characterized in that, The male core component (101) includes a linearly extending magnetic core (103), and the female core component (102) includes a receiving portion for receiving the end section of the magnetic core (103).

7. The inductor structure according to claim 6, characterized in that, The male skeleton component (201) includes a linearly extending first hollow sleeve (203), and the female skeleton component (202) includes a linearly extending second hollow sleeve (204). The first hollow sleeve (203) and the second hollow sleeve (204) are detachably connected.

8. The inductor structure according to claim 7, characterized in that, The inner diameters of the first hollow sleeve (203) and the second hollow sleeve (204) are both larger than the diameter of the magnetic core (103).

9. The inductor structure according to claim 7, characterized in that, The outer diameters of the first hollow sleeve (203) and the second hollow sleeve (204) are both smaller than the inner diameter of the annular flat wire coil (300).

10. A power factor corrector, characterized in that, Including the inductor structure according to any one of claims 1-9.

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