High-energy-storage inductor

Abstract

The utility model provides a high energy storage inductor which comprises a framework, a coil winding, two groups of magnetic cores, a first insulating layer, a second insulating layer and two insulating plastic covers, the framework comprises an upper baffle, a middle column ring and a lower baffle, and each magnetic core comprises a magnetic column, an upper magnetic plate, a lower magnetic plate and two magnetic arms. The first insulating layer is wound on the outer side surfaces of the upper magnetic plate, the lower magnetic plate and the two magnetic arms of the two groups of magnetic cores, the second insulating layer is wound on the periphery of the coil winding, the periphery of a wire of the coil winding is wrapped with a varnished film, and the two insulating plastic covers oppositely cover a peripheral opening. And one insulating plastic cover is positioned between the second insulating layer and the magnetic arms on the same side of the two groups of magnetic cores. In the assembling production process of the high-energy-storage inductor, not only can the coil winding be prevented from being damaged, but also the insulating property can be enhanced, so that the production quality of products is improved, the potential safety hazard of the products is avoided, the service life of the products is prolonged, and the high-energy-storage inductor is ensured to operate efficiently, stably and safely and is safer and more reliable.

Description

Technical Field

[0001] This utility model relates to the field of electromagnetic components technology, and in particular to a high-energy-storage inductor. Background Technology

[0002] A high-energy-storage PFC inductor is an inductor used for power factor correction (PFC), typically in inductor-compensated PFC circuits and active PFC circuits. The PFC inductor plays a crucial role; its main purpose is to smooth the input current waveform and synchronize it with the input voltage waveform through its energy storage and filtering characteristics, thereby improving the power factor. Specifically, when the voltage sine wave is at its peak, the inductor stores energy; when the voltage drops, the inductor releases energy, thus maintaining the continuity and stability of the input current.

[0003] See Figure 1 The existing inductor uses the central column of the frame 1 and the baffles 12 set on both sides of the frame 1 to form a winding receiving cavity, so that the coil winding 2 is wound on the central column of the frame 1 and located in the winding receiving cavity formed by the baffles 12 on both sides and the central column. Then, the two opposite outer magnetic arms of the E-type magnet 5 are sleeved on the outer periphery of the coil winding 2, and the pins 3 are set on the mounting plate of the frame 1.

[0004] Because the existing inductor assembly process involves first winding the coil winding 2 onto the center post of the frame 1, and then installing the E-type magnet 5, in the actual inductor assembly process, after the winding step of winding the coil winding 2 onto the center post of the frame 1 is completed, the outer periphery of the coil winding 2 is prone to protruding from the winding receiving cavity in the radial direction of the center post. This causes the outer periphery of the coil winding 2 to protrude from the baffle 12 in the radial direction of the center post. As a result, during the subsequent installation of the E-type magnet 5, the two outer magnetic arms of the E-type magnet 5 will rub and squeeze the outer periphery of the coil winding 2 that protrudes from the baffle 12, which can cause damage and cracking of the coil enamel coating of the coil winding 2, and even damage to the coil of the coil winding 2. This affects the service life of the coil winding 2, affects the insulation performance, and thus creates safety hazards. Summary of the Invention

[0005] To achieve the main objective of this utility model, it provides a high-energy-storage inductor that, during assembly and production, not only prevents damage to the coil windings but also enhances insulation performance, thereby improving product quality, eliminating safety hazards, extending product lifespan, and ensuring efficient, stable, and safe operation. This makes the product safer and more reliable to use, and enables automated and efficient assembly and production with good product consistency.

[0006] To achieve the main objective of this utility model, a high-energy-storage inductor is provided, comprising a frame, a coil winding, two sets of magnetic cores, a first insulating layer, a second insulating layer, and two insulating plastic covers. The frame includes an upper baffle, a middle cylindrical ring, and a lower baffle, which are located at the axial ends of the middle cylindrical ring, respectively. An outer annular cavity with an open outer periphery is formed between the middle cylindrical ring, the upper baffle, and the lower baffle. The coil winding is wound inside the outer annular cavity, and the lead-out end of the coil winding extends out of either the upper or lower baffle. The two sets of magnetic cores are arranged adjacent to each other in the radial direction of the middle cylindrical ring. Each magnetic core includes a magnetic column, an upper magnetic plate, and a lower magnetic plate. The device consists of two magnetic arms. The upper magnetic plate is located at the upper end of the upper baffle, and the lower magnetic plate is located at the lower end of the lower baffle. The magnetic column is located in the annular hole of the middle column ring and is connected between the upper and lower magnetic plates. The two magnetic arms are located on opposite sides of the outer annular cavity and are connected between the upper and lower magnetic plates. The first insulating layer is wound on the outer surfaces of the upper magnetic plate, the lower magnetic plate, and the two magnetic arms of the two sets of magnetic cores. The second insulating layer is wound on the outer periphery of the coil winding. The outer periphery of the coil winding wire is wrapped with an enameled film. Two insulating plastic covers are arranged opposite each other and cover the outer periphery opening. One insulating plastic cover is located between the second insulating layer and the magnetic arm on the same side of the two sets of magnetic cores.

[0007] As can be seen from the above scheme, the high-energy storage inductor of this utility model adopts two sets of magnetic cores arranged adjacent to each other in the radial direction of the central ring of the skeleton, which doubles the cross-sectional area of ​​the magnetic components in the radial direction of the central ring of the skeleton, thereby increasing the power density of the inductor, achieving stable output and improving energy storage conversion efficiency, thus realizing the high energy storage performance of the inductor. Furthermore, since the cross-sectional area of ​​the magnetic components in the radial direction of the central ring of the skeleton is increased, the number of turns ratio of the coil winding can be reduced accordingly, so that the coil winding can save more material, saving costs while better meeting the requirements of high energy storage performance. Furthermore, the outer periphery of the coil winding wire of the high-energy storage inductor of this invention is wrapped with an enameled film, which provides a layer of insulation and protection for the coil winding wire. The second insulation layer is wound around the outer periphery of the coil winding, providing a second layer of insulation and protection for the entire coil winding. Two insulating plastic covers are positioned opposite each other and cover the outer periphery opening of the outer ring cavity. One insulating plastic cover is located between the second insulation layer and the magnetic arm on the same side of the two sets of magnetic cores, providing a third layer of insulation and protection for the second insulation layer and the coil winding, greatly enhancing the insulation performance. In addition, the first insulation layer is wound around the outer surface of the upper magnetic plate, lower magnetic plate and the two magnetic arms of the two sets of magnetic cores, further improving the insulation performance. In the automated and efficient assembly and production process of this high-energy storage inductor, the coil winding is first automatically wound into the outer ring cavity formed between the upper baffle, middle column ring and lower baffle of the frame. Then, the second insulating layer is wound around the outer periphery of the coil winding. Next, two insulating plastic covers are placed on the outer periphery opening of the outer ring cavity. Then, two sets of magnetic cores are installed. Finally, the first insulating layer is wound around the outer surface of the upper magnetic plate, lower magnetic plate and two magnetic arms of the two sets of magnetic cores. Because this high-energy storage inductor utilizes an enameled film to provide a first layer of insulation and protection for the coil winding wire, a second insulation layer to provide a second layer of insulation and protection for the entire coil winding, and an insulating plastic cover to provide a third layer of insulation and protection for both the second insulation layer and the coil winding, with one insulating plastic cover located between the second insulation layer and the magnetic arm on the same side of the two sets of magnetic cores, damage to the coil winding wire can be prevented during the installation of the two sets of magnetic cores. This improves the production quality of the high-energy storage inductor, eliminates potential safety hazards, and extends the service life of the wire. Therefore, in the automated and efficient assembly and production process, this high-energy storage inductor not only prevents damage to the coil winding but also enhances insulation performance, thereby improving product quality, eliminating potential safety hazards, extending product life, and ensuring efficient, stable, and safe operation. This makes the product safer and more reliable to use, and enables automated and efficient assembly and production with good product consistency.

[0008] A further embodiment is that each insulating plastic cover includes a first cover plate, a second cover plate, and a third cover plate connected in sequence. The first cover plate is located between the upper magnetic plate and the upper baffle at the upper end. The second cover plate covers the outer peripheral opening and is located between the second insulating layer and the same side magnetic arm of the two sets of magnetic cores. The third cover plate is located between the lower magnetic plate and the lower baffle at the lower end.

[0009] A further option is that the outer periphery of the coil winding is wound with at least two layers of second insulation; and / or, the second insulation layer is insulating tape.

[0010] A further option is that the outer surfaces of the upper and lower magnetic plates and the two magnetic arms of the two sets of magnetic cores are wrapped with multiple layers of the first insulating layer; and / or, the first insulating layer is insulating tape.

[0011] A further embodiment is that the upper end of the upper baffle is provided with a first limiting groove, the upper magnetic plates of the two sets of magnetic cores are located in the first limiting groove, and there is a first heat dissipation gap between the upper magnetic plates of the two sets of magnetic cores and the groove sidewall of the first limiting groove; and / or, the lower end of the lower baffle is provided with a second limiting groove, the lower magnetic plates of the two sets of magnetic cores are located in the second limiting groove, and there is a second heat dissipation gap between the lower magnetic plates of the two sets of magnetic cores and the groove sidewall of the second limiting groove.

[0012] A further embodiment is that the sidewall of the first limiting groove is provided with a plurality of first positioning ribs protruding outwards, and the outer convex surface of the first positioning ribs abuts against the peripheral side surface of the upper magnetic plate; and / or, the sidewall of the second limiting groove is provided with a plurality of second positioning ribs protruding outwards, and the outer convex surface of the second positioning ribs abuts against the peripheral side surface of the lower magnetic plate.

[0013] A further option is that a first heat dissipation groove is provided through the opposite sides of the upper baffle, and the two first heat dissipation grooves and the two magnetic arms are alternately arranged in the circumferential direction of the middle column ring; and / or, a second heat dissipation groove is provided through the opposite sides of the lower baffle, and the two second heat dissipation grooves and the two magnetic arms are alternately arranged in the circumferential direction of the middle column ring.

[0014] A further option is that the upper end of the upper baffle is provided with four positioning holes, which are respectively located at the four corners of the upper baffle; and / or, the lower end of the lower baffle is provided with a support plate, the lower end of the support plate protruding outward from the first insulating layer in the axial direction of the central column ring, so that the lower end of the support plate has a third heat dissipation gap between the outer periphery of the first insulating layer and the central column ring in the axial direction.

[0015] A further solution is to provide four sets of positioning structures at the lower end of the lower baffle. The four sets of positioning structures are respectively located at the four corners of the lower baffle. Each set of positioning structures includes two positioning posts. The positioning end of each positioning post protrudes outward from the lower end of the support plate along the axial direction of the middle column ring.

[0016] A further embodiment is that each magnetic column includes a first sub-column and a second sub-column, and each magnetic arm includes a first sub-arm and a second sub-arm. One first sub-column and two first sub-arms are disposed on the inner end face of an upper magnetic plate, and one second sub-column and two second sub-arms are disposed on the inner end face of a lower magnetic plate. The first sub-column and the second sub-column abut against each other in the axial direction of the middle column ring, and one first sub-arm and one second sub-arm abut against each other in the axial direction of the middle column ring. The positions where one first sub-arm and one second sub-arm abut against each other in the axial direction of the middle column ring are fixedly connected by epoxy resin adhesive. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of an existing inductor.

[0018] Figure 2 This is a first-view structural diagram of an embodiment of a high-energy storage inductor according to this utility model.

[0019] Figure 3 This is a second-view structural diagram of an embodiment of a high-energy storage inductor according to this utility model.

[0020] Figure 4 This is an exploded view of an embodiment of a high-energy storage inductor according to the present invention.

[0021] Figure 5 This is a first-view sectional view of an embodiment of a high-energy storage inductor according to this utility model.

[0022] Figure 6 This is a second-view sectional view of an embodiment of a high-energy storage inductor according to this utility model.

[0023] Figure 7 This is a structural diagram showing the assembly of the frame, coil winding, second insulating layer, and two insulating plastic caps in an embodiment of a high-energy storage inductor of this utility model.

[0024] Figure 8 This is a cross-sectional view of the skeleton, coil winding, second insulating layer and two insulating plastic caps in an embodiment of a high energy storage inductor of this utility model.

[0025] Figure 9 This is a first-view structural diagram of the skeleton in an embodiment of a high-energy storage inductor of this utility model.

[0026] Figure 10 This is a second-view structural diagram of the skeleton in an embodiment of a high-energy storage inductor of this utility model.

[0027] Figure 11 This is a structural diagram of the E-type support core in an embodiment of a high-energy storage inductor of this utility model.

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0029] See Figures 2 to 11 This embodiment discloses a high-energy-storage inductor 10, including a frame 14, a coil winding 15, and two sets of magnetic cores. The frame 14 includes an upper baffle 142, a middle column ring 141, and a lower baffle 143. The upper baffle 142 and the lower baffle 143 are respectively located at the two axial ends of the middle column ring 141. An outer ring cavity 144 with an outer peripheral opening is formed between the middle column ring 141, the upper baffle 142, and the lower baffle 143. The coil winding 15 is wound in the outer ring cavity 144, and the lead end of the coil winding 15 passes through the upper baffle 142 or the lower baffle 143. The two sets of magnetic cores are located in the middle column ring. The rings 141 are arranged side by side in the radial direction. Each magnetic core includes magnetic pillars 172 and 175, an upper magnetic plate 171, a lower magnetic plate 174, and two magnetic arms 173 and 176. The upper magnetic plate 171 is located at the upper end of the upper baffle 142, and the lower magnetic plate 174 is located at the lower end of the lower baffle 143. The magnetic pillars 172 and 175 are located in the annular hole 1411 of the middle pillar ring 141 and are connected between the upper magnetic plate 171 and the lower magnetic plate 174. The two magnetic arms 173 and 176 are located on the opposite outer side of the outer annular cavity 144 and are connected between the upper magnetic plate 171 and the lower magnetic plate 174. Furthermore, the high-energy storage inductor 10 in this embodiment also includes a first insulating layer 11, a second insulating layer 13, and two insulating plastic covers 16. The first insulating layer 11 is wound around the outer surfaces of the upper magnetic plate 171, the lower magnetic plate 174, and the two magnetic arms 173 and 176 of the two sets of magnetic cores. The second insulating layer 13 is wound around the outer periphery of the coil winding 15. The outer periphery of the wire 151 of the coil winding 15 is wrapped with an enameled film 152. The two insulating plastic covers 16 are arranged opposite to each other and cover the outer periphery opening of the outer ring cavity 144. One insulating plastic cover 16 is located between the second insulating layer 13 and the magnetic arms 173 and 176 on the same side of the two sets of magnetic cores.

[0030] In this embodiment, the high-energy-storage inductor 10 employs two sets of magnetic cores arranged adjacent to each other in the radial direction of the central ring 141 of the frame 14. This doubles the cross-sectional area of ​​the magnetic components in the radial direction of the central ring 141 of the frame 14, thereby increasing the power density of the inductor 10, achieving stable output and improving energy storage conversion efficiency. This results in high energy storage performance of the inductor 10. Furthermore, due to the increased cross-sectional area of ​​the magnetic components in the radial direction of the central ring 141 of the frame 14, the turns ratio of the coil winding 15 can be reduced accordingly, allowing the coil winding 15 to save materials, saving costs while better meeting the requirements of high energy storage performance.

[0031] Furthermore, in this embodiment, the outer periphery of the wire 151 of the coil winding 15 of the high-energy storage inductor 10 is wrapped with an enameled film 152. The enameled film 152 provides a layer of insulation and protection for the wire 151 of the coil winding 15. The second insulation layer 13 is wound around the outer periphery of the coil winding 15, providing a second layer of insulation and protection for the entire coil winding 15. Two insulating plastic covers 16 are arranged opposite to each other and cover the outer periphery opening of the outer ring cavity 144. One insulating plastic cover 16 is located between the second insulation layer 13 and the magnetic arms 173 and 176 on the same side of the two sets of magnetic cores. The insulating plastic cover 16 provides a third layer of insulation and protection for the second insulation layer 13 and the coil winding 15, greatly enhancing the insulation performance. In addition, the first insulation layer 11 is wound around the outer surface of the upper magnetic plate 171, the lower magnetic plate 174 and the two magnetic arms 173 and 176 of the two sets of magnetic cores, further improving the insulation performance.

[0032] In the automated and efficient assembly and production process of the high-energy storage inductor 10 in this embodiment, the coil winding 15 is first automatically wound into the outer ring cavity 144 formed between the upper baffle 142, the middle column ring 141 and the lower baffle 143 of the frame 14. Then, the second insulating layer 13 is wound around the outer periphery of the coil winding 15. Next, two insulating plastic covers 16 are placed on the outer periphery opening of the outer ring cavity 144. Then, two sets of magnetic cores are installed. Finally, the first insulating layer 11 is wound around the outer surface of the upper magnetic plate 171, the lower magnetic plate 174 and the two magnetic arms 173 and 176 of the two sets of magnetic cores. In this embodiment, the high-energy storage inductor 10 uses an enameled film 152 to provide a layer of insulation and protection for the wire 151 of the coil winding 15, a second insulation layer 13 to provide a second layer of insulation and protection for the entire coil winding 15, and an insulating plastic cover 16 to provide a third layer of insulation and protection for the second insulation layer 13 and the coil winding 15. Furthermore, an insulating plastic cover 16 is located between the second insulation layer 13 and the magnetic arms 173 and 176 on the same side of the two sets of magnetic cores. This prevents damage to the wire 151 of the coil winding 15 from the magnetic cores during the installation of the two sets of magnetic cores, thereby improving the production quality of the high-energy storage inductor 10, eliminating potential safety hazards, and extending the service life of the wire 151.

[0033] Therefore, in the automated and efficient assembly and production process of the high-energy storage inductor 10 in this embodiment, not only can damage to the coil winding 15 be prevented, but insulation performance can also be enhanced, thereby improving product quality, eliminating product safety hazards, extending product life, and ensuring efficient, stable and safe operation of the product. This makes the product safer and more reliable to use, and enables automated and efficient assembly and production with good product consistency.

[0034] Combination Figures 4 to 8In this embodiment, each insulating plastic cover 16 includes a first cover plate 161, a second cover plate 162, and a third cover plate 163 connected in sequence. The first cover plate 161 is located between the upper magnetic plate 171 and the upper baffle 142. The second cover plate 162 covers the outer peripheral opening of the outer annular cavity 144 and is located between the second insulating layer 13 and the same side magnetic arms 173 and 176 of the two sets of magnetic cores. The third cover plate 163 is located between the lower magnetic plate 174 and the lower baffle 143, thereby ensuring that the second cover plate 162 of the insulating plastic cover 16 is stably covered at the outer peripheral opening of the outer annular cavity 144 and is located between the second insulating layer 13 and the same side magnetic arms 173 and 176 of the two sets of magnetic cores.

[0035] To further improve insulation performance, at least two layers of second insulation layer 13 are wound around the outer periphery of the coil winding 15 in this embodiment. Specifically, the second insulation layer 13 in this embodiment is insulating tape, which can be firmly and adhesively wound around the outer periphery of the coil winding 15.

[0036] To further improve insulation performance, in this embodiment, multiple layers of first insulation 11 are wound around the outer surfaces of the upper magnetic plate 171, lower magnetic plate 174, and two magnetic arms 173 and 176 of the two sets of magnetic cores. Specifically, in this embodiment, the first insulation layer 11 is insulating tape, which can be adhesively and securely wound around the outer surfaces of the upper magnetic plate 171, lower magnetic plate 174, and two magnetic arms 173 and 176 of the two sets of magnetic cores.

[0037] Combination Figure 9 and Figure 10 In this embodiment, the upper end of the upper baffle 142 is provided with a first limiting groove 145, and the upper magnetic plates 171 of the two sets of magnetic cores are located in the first limiting groove 145, thereby keeping the upper magnetic plates 171 confined within the first limiting groove 145 of the upper baffle 142. Furthermore, there is a first heat dissipation gap 18 between the upper magnetic plates 171 of the two sets of magnetic cores and the groove sidewall of the first limiting groove 145, allowing air to flow through the first heat dissipation gap 18, thereby dissipating heat from the upper magnetic plates 171. Furthermore, in this embodiment, a second limiting groove 146 is provided at the lower end of the lower baffle 143, and the lower magnetic plates 174 of the two sets of magnetic cores are located in the second limiting groove 146, thereby keeping the lower magnetic plates 174 confined within the second limiting groove 146 of the lower baffle 143. A second heat dissipation gap 19 is provided between the lower magnetic plates 174 of the two sets of magnetic cores and the groove sidewall of the second limiting groove 146, allowing air to flow through the second heat dissipation gap 19, thereby dissipating heat from the lower magnetic plates 174.

[0038] To ensure a stable first heat dissipation gap 18 between the upper magnetic plate 171 and the sidewall of the first limiting groove 145 for effective heat dissipation, the sidewall of the first limiting groove 145 in this embodiment is provided with a plurality of first positioning ribs (not shown), the outer convex surfaces of which abut against the peripheral sidewall of the upper magnetic plate 171. Furthermore, to ensure a stable second heat dissipation gap 19 between the lower magnetic plate 174 and the sidewall of the second limiting groove 146 for effective heat dissipation, the sidewall of the second limiting groove 146 in this embodiment is provided with a plurality of second positioning ribs 1461, the outer convex surfaces of which abut against the peripheral sidewall of the lower magnetic plate 174.

[0039] To further improve heat dissipation, in this embodiment, first heat dissipation grooves 149 are provided through the opposite sides of the upper baffle 142. The two first heat dissipation grooves 149 and the two magnetic arms 173 and 176 are alternately arranged in the circumferential direction of the central column ring 141. In addition, in this embodiment, second heat dissipation grooves 1410 are provided through the opposite sides of the lower baffle 143. The two second heat dissipation grooves 1410 and the two magnetic arms 173 and 176 are alternately arranged in the circumferential direction of the central column ring 141. This allows the first heat dissipation grooves 149 at the top and the second heat dissipation grooves 1410 at the bottom to form air convection, allowing air to enter the coil winding 15 and carry away heat. This prevents excessive heat inside the coil winding 15 from causing damage, thereby extending the product's service life and ensuring the product's efficient, stable, and safe operation.

[0040] In this embodiment, the upper end of the upper baffle 142 is provided with four positioning holes 147. The four positioning holes 147 are respectively located at the four corners of the upper baffle 142. The positioning holes 147 at the upper end of the upper baffle 142 can match and position with the upper cover on which the inductor 10 is installed, thereby ensuring that the inductor 10 is accurately assembled with the upper cover on which it is installed, and avoiding misalignment during assembly.

[0041] Furthermore, in this embodiment, a support plate 1412 is provided at the lower end of the lower baffle 143. The lower end of the support plate 1412 protrudes outward from the first insulating layer 11 in the axial direction of the central column ring 141, so that the lower end of the support plate 1412 has a third heat dissipation gap (not shown) between the central column ring 141 and the outer periphery of the first insulating layer 11 in the axial direction of the support plate 1412. Thus, in this embodiment, when the inductor 10 is inserted into the circuit board, the support plate 1412 can abut against the circuit board to support the entire inductor 10. The third heat dissipation gap between the lower end of the support plate 1412 and the outer periphery of the first insulating layer 11 in the axial direction of the central column ring 141 ensures that there is a third heat dissipation gap between the bottom of the first insulating layer 11 on the outer surface of the upper magnetic plate 171, lower magnetic plate 174 and the two magnetic arms 173, 176 wound around the two sets of magnetic cores and the circuit board, allowing air to flow through the third heat dissipation gap, thereby dissipating heat from the lower magnetic plate 174.

[0042] In addition, in this embodiment, the lower end of the lower baffle 143 is provided with four sets of positioning structures. The four sets of positioning structures are respectively set at the four corners of the lower baffle 143. Each set of positioning structures includes two positioning posts 148. The positioning end of each positioning post 148 is set to protrude outward from the lower end of the support plate 1412 in the axial direction of the middle post ring 141. The positioning post 148 can accurately position the plug-in, and the plug-in speed is fast and the plug-in efficiency is high, which improves the assembly production efficiency.

[0043] Combination Figure 11 In this embodiment, each magnetic post 172, 175 includes a first sub-post 172 and a second sub-post 175, and each magnetic arm 173, 176 includes a first sub-arm 173 and a second sub-arm 176. One first sub-post 172 and two first sub-arms 173 are disposed on the inner end face of an upper magnetic plate 171, and one second sub-post 175 and two second sub-arms 176 are disposed on the inner end face of a lower magnetic plate 174. The first sub-post 172 and the second sub-post 175 abut against each other axially in the middle post ring 141, and one first sub-arm 173 and one second sub-arm 176 abut against each other axially in the middle post ring 141. By disassembling the magnetic core of this embodiment into two components, namely two E-type support cores 17, the assembly speed of the magnetic core can be improved, further improving the production efficiency of the high-energy storage inductor 10.

[0044] To ensure the stability and reliability of assembling the two E-type support cores 17 into a single magnetic core, in this embodiment, a first branch arm 173 and a second branch arm 176 are fixedly connected at the position where they abut against each other in the axial direction of the central column ring 141 by epoxy resin adhesive 12. Epoxy resin adhesive 12 has advantages such as high bonding strength, high temperature resistance, and good thermal conductivity.

[0045] The above embodiments are merely preferred examples of this utility model and are not intended to limit the scope of implementation of this utility model. Therefore, all equivalent changes or modifications made to the structure, features and principles of this utility model patent application should be included within the scope of this utility model patent application.

Claims

1. A high-energy-storage inductor, comprising a frame, a coil winding, and two sets of magnetic cores, wherein the frame includes an upper baffle, a middle cylindrical ring, and a lower baffle, the upper baffle and the lower baffle being located at opposite axial ends of the middle cylindrical ring, forming an outer annular cavity with an open outer periphery between the middle cylindrical ring, the coil winding being wound within the outer annular cavity, and the lead-out end of the coil winding passing through either the upper baffle or the lower baffle, two magnetic cores being arranged adjacent to each other radially within the middle cylindrical ring, each magnetic core including a magnetic column, an upper magnetic plate, a lower magnetic plate, and two magnetic arms, the upper magnetic plate being located at the upper end of the upper baffle, the lower magnetic plate being located at the lower end of the lower baffle, the magnetic column being located within an annular hole of the middle cylindrical ring and connected between the upper magnetic plate and the lower magnetic plate, and the two magnetic arms being located on opposite outer sides of the outer annular cavity and connected between the upper magnetic plate and the lower magnetic plate, characterized in that: The high-energy storage inductor also includes a first insulating layer, a second insulating layer and two insulating plastic caps. The first insulating layer is wound around the outer surfaces of the upper magnetic plate, the lower magnetic plate and the two magnetic arms of the two magnetic cores. The second insulating layer is wound around the outer periphery of the coil winding. The outer periphery of the wire of the coil winding is wrapped with an enameled film. Two insulating plastic covers are disposed opposite to each other and cover the outer peripheral opening, with one of the insulating plastic covers located between the second insulating layer and the magnetic arms on the same side of the two magnetic cores.

2. The high-energy storage inductor according to claim 1, characterized in that: Each of the insulating plastic covers includes a first cover plate, a second cover plate, and a third cover plate connected in sequence. The first cover plate is located between the upper magnetic plate and the upper baffle at the upper end. The second cover plate covers the outer peripheral opening and is located between the second insulating layer and the magnetic arms on the same side of the two magnetic cores. The third cover plate is located between the lower magnetic plate and the lower baffle at the lower end.

3. The high-energy storage inductor according to claim 1, characterized in that: The outer periphery of the coil winding is wound with at least two layers of the second insulating layer; And / or, the second insulating layer is insulating tape.

4. The high-energy storage inductor according to claim 1, characterized in that: The outer surfaces of the upper magnetic plate, the lower magnetic plate, and the two magnetic arms of the two magnetic cores are wound with multiple layers of the first insulating layer; And / or, the first insulating layer is insulating tape.

5. The high-energy storage inductor according to claim 1, characterized in that: The upper end of the upper baffle is provided with a first limiting groove, the upper magnetic plates of the two magnetic cores are located in the first limiting groove, and there is a first heat dissipation gap between the upper magnetic plates of the two magnetic cores and the groove sidewall of the first limiting groove. And / or, the lower end of the lower baffle is provided with a second limiting groove, the lower magnetic plates of the two magnetic cores are located in the second limiting groove, and there is a second heat dissipation gap between the lower magnetic plates of the two magnetic cores and the groove sidewall of the second limiting groove.

6. The high-energy storage inductor according to claim 5, characterized in that: The first limiting groove has a plurality of first positioning ribs protruding from its sidewall, and the outer convex surface of the first positioning ribs abuts against the peripheral side surface of the upper magnetic plate. And / or, the sidewall of the second limiting groove is provided with a plurality of second positioning ribs, the outer convex surface of the second positioning ribs abutting against the peripheral side surface of the lower magnetic plate.

7. The high-energy storage inductor according to claim 1, characterized in that: The upper baffle has first heat dissipation slots through its opposite sides, and the two first heat dissipation slots and the two magnetic arms are arranged alternately in the circumferential direction of the middle column ring. And / or, the lower baffle is provided with second heat dissipation grooves through its opposite sides, and the two second heat dissipation grooves and the two magnetic arms are arranged alternately in the circumferential direction of the central column ring.

8. The high-energy storage inductor according to claim 1, characterized in that: The upper end of the upper baffle is provided with four positioning holes, which are respectively located at the four corners of the upper baffle. And / or, the lower end of the lower baffle is provided with a support plate, the lower end of the support plate protruding outward from the first insulating layer in the axial direction of the middle column ring, so that the lower end of the support plate has a third heat dissipation gap between the middle column ring and the outer periphery of the first insulating layer in the axial direction of the middle column ring.

9. The high-energy storage inductor according to claim 8, characterized in that: The lower end of the lower baffle is provided with four sets of positioning structures. The four sets of positioning structures are respectively located at the four corners of the lower baffle. Each set of positioning structures includes two positioning posts. The positioning end of each positioning post protrudes outward from the lower end of the support plate in the axial direction of the middle column ring.

10. The high-energy storage inductor according to any one of claims 1 to 9, characterized in that: Each of the magnetic pillars includes a first sub-pillar and a second sub-pillar, and each of the magnetic arms includes a first sub-arm and a second sub-arm. One first sub-pillar and two first sub-arms are disposed on the inner end face of an upper magnetic plate, and one second sub-pillar and two second sub-arms are disposed on the inner end face of a lower magnetic plate. The first and second sub-posts abut against each other in the axial direction of the central pillar ring, and one of the first and one of the second sub-arms abut against each other in the axial direction of the central pillar ring. The positions where the first and second sub-arms abut against each other in the axial direction of the central pillar ring are fixedly connected by epoxy resin adhesive.

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