High-power inductor

Abstract

The utility model relates to a high-power inductor which comprises a first magnetic core, a first framework, a middle winding assembly, a second framework, a second magnetic core and a shell. The first magnetic core is installed on one side of the first framework, the middle winding assembly is installed between the other side of the first framework and one side of the second framework, and the second magnetic core is installed on the other side of the second framework to form a magnetic core assembly. The magnetic core assembly is installed in the shell. The middle winding assembly comprises at least two middle column magnetic cores, and each middle column magnetic core is recessed relative to the first magnetic core and the second magnetic core to form a groove. The utility model can improve the heat dissipation effect, and is applied to the technical field of electronic components.

Description

Technical Field

[0001] This utility model relates to the field of electronic component technology, and in particular to a high-power inductor. Background Technology

[0002] In related technologies, the coils of inductors generate a lot of heat during operation. This heat accumulates in the coils, causing them to reach high temperatures. Over time, this can easily lead to coil aging. Existing water-cooled high-power inductors have an issue where the overall design is too far from the water-cooling plate, resulting in poor heat dissipation. Utility Model Content

[0003] In view of this, the purpose of this utility model embodiment is to provide a high-power inductor that can improve heat dissipation.

[0004] To solve one of the above problems, this utility model provides a high-power inductor, including a first magnetic core, a first frame, an intermediate winding assembly, a second frame, a second magnetic core, and a housing;

[0005] The first magnetic core is mounted on one side of the first frame, the intermediate winding assembly is mounted between the other side of the first frame and one side of the second frame, and the second magnetic core is mounted on the other side of the second frame, forming a magnetic core assembly; the magnetic core assembly is mounted in the housing.

[0006] The intermediate winding assembly includes at least two central cores, each of which is recessed relative to the first and second cores to form a groove.

[0007] Optionally, each of the central cores is wound with a winding; a contoured heat dissipation structure is provided between the two central cores inside the housing, and the contoured heat dissipation structure is in the shape of an inverted triangle to match the winding.

[0008] Optionally, each of the central cores includes at least two core blocks, and at least one layer of adhesive is provided between two adjacent core blocks, between the central core and the first frame, and between the central core and the second frame.

[0009] Optionally, the width-to-height ratio of the central core is 0.5-1.

[0010] Optionally, at least three first limiting rubber strips are provided on one side of the first skeleton, and the first magnetic core is installed between the first limiting rubber strips.

[0011] Optionally, a plurality of second limiting rubber strips are provided on the other side of the first frame and on one side of the second frame, and the intermediate winding assembly is installed between the second limiting rubber strips.

[0012] Optionally, the second frame is provided with at least two electrical terminals, and one end of each winding is welded to one of the electrical terminals.

[0013] Optionally, the central core is wrapped with at least one layer of insulating paper.

[0014] Optionally, the other two ends of the second frame are respectively provided with bosses, the bosses are provided with first mounting holes, and the housing is provided with second mounting holes that cooperate with the first mounting holes.

[0015] Optionally, the height of the housing surrounding the second frame is lower than the height surrounding the first frame and the intermediate winding assembly.

[0016] This invention has the following beneficial effects: When designing the overall layout of the inductor, the mounting surface of one of the central cores of each intermediate winding assembly is offset from the mounting surface of the same side of the first and second cores, so that the central core is recessed relative to the first and second cores to form a groove, that is, the cores are asymmetrically mounted, and a groove is formed between the first and second cores, which makes the central core sink, effectively reducing the overall height of the product, thereby reducing the heat dissipation distance of the water-cooled plate and achieving the purpose of improving the heat dissipation effect. Attached Figure Description

[0017] Wherein: 1-first magnetic core, 2-first frame, 3-intermediate winding assembly, 4-second frame, 5-second magnetic core, 6-shell, 21-first limiting adhesive strip, 31-central column magnetic core, 32-winding, 311-fixing adhesive, 312-air gap gasket, 313-magnetic core block, 41-second limiting adhesive strip, 42-electrical terminal, 43-protrusion, 44-reinforcing rib, 61-contour heat dissipation structure, 62-the part of the shell surrounding the second frame.

[0018] Figure 1 This is a schematic diagram of the structure of a high-power inductor provided by this utility model;

[0019] Figure 2 This is a schematic diagram of the structure of a shell provided by this utility model;

[0020] Figure 3 This is an installation diagram of a central core and two end cores provided by this utility model;

[0021] Figure 4 This is an exploded view of an intermediate winding assembly provided by this utility model;

[0022] Figure 5 This is a schematic diagram of one side of the first skeleton provided by this utility model;

[0023] Figure 6This is a structural schematic diagram of the other side of the first frame and one side of the second frame provided by this utility model;

[0024] Figure 7 This is a top view of a second skeleton provided by this utility model. Detailed Implementation

[0025] To facilitate understanding of this utility model, a more detailed description will be provided below with reference to the accompanying drawings and specific embodiments. It should be noted that when an element is described as "connected" to another element, it can be directly on the other element, or one or more intermediate elements may exist between them.

[0026] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention.

[0027] Please see Figure 1-3 , Figure 1 This is a schematic diagram of the structure of a high-power inductor. Figure 2 This is a schematic diagram of the structure of a shell 6. Figure 3 This is a schematic diagram of the installation of a central core 31 and two end cores. This utility model provides a high-power inductor, including a first core 1, a first frame 2, an intermediate winding assembly 3, a second frame 4, a second core 5, and a housing 6; the first core 1 is installed on one side of the first frame 2, the intermediate winding assembly 3 is installed on the other side of the first frame 2 and between one side of the second frame 4, and the second core 5 is installed on the other side of the second frame 4, forming a core assembly; the core assembly is installed in the housing 6; the intermediate winding assembly 3 includes at least two central cores 31, each central core being recessed relative to the first and second cores to form a groove, such as... Figure 3 As shown in the figure, one mounting surface of the central core 31 is lower than the mounting surfaces of the first core 1 and the second core 5 on the same side.

[0028] like Figure 3 As shown, when the lengths of the first magnetic core 1 and the second magnetic core 5 are not equal to the length of the central core 31, one mounting surface of the central core 31 is lower than the mounting surfaces of the first magnetic core 1 and the second magnetic core 5 on the same side as the mounting surface of the central core 31. This can be explained as the midpoints of the long sides of the first magnetic core 1 and the second magnetic core 5 and the midpoint of the long side of the central core 31 are not on the same straight line. Consequently, the central core 31 sinks relative to the first magnetic core 1 and the second magnetic core 5, and the first magnetic core 1, the central core 31 and the second magnetic core 5 are asymmetrically assembled to form a groove.

[0029] Specifically, a magnetic core assembly is placed inside the housing 6, and potting compound is applied between the magnetic core assembly and the housing 6. The magnetic core assembly, from one end to the other, sequentially includes a first magnetic core 1, a first frame 2, an intermediate winding assembly 3, a second frame 4, and a second magnetic core 5. The housing 6 can be, but is not limited to, a die-cast aluminum shell, and the bottom outer surface is machined to control surface roughness, with a roughness less than or equal to 0.8 micrometers. The water-cooled inductor will be mounted on a water-cooling plate, and the bottom surface of the housing 6 will be in close contact with the water-cooling plate. Better surface roughness allows for better contact with the water-cooling plate and accelerates heat dissipation.

[0030] Encapsulating adhesives can be, but are not limited to, two-component silicone encapsulating adhesives. They encapsulate and cover the magnetic core assembly within the casing, cure at room temperature, and provide thermal conductivity and overall protection for the magnetic core assembly. The thermal conductivity of the adhesive can be selected based on the inductor's heat generation. Commonly used encapsulating adhesives have thermal conductivity ranging from 0.8 to 3.0 W / m*K. Higher thermal conductivity results in better inductor heat dissipation and lower operating temperatures.

[0031] The dimensions of the first magnetic core 1 and the second magnetic core 5 are larger than the dimensions of the central core 31. The length of the first magnetic core 1 and the second magnetic core 5 is equal to twice the sum of the length of the central core 31 and the width of the copper wire plus the reserved gap in the coil. Here, the length refers to the length of the longer side parallel to the first frame 2. To keep the change in Ae in the magnetic circuit of the core small, the product of the width and height of the first magnetic core 1 and the second magnetic core 5 is close to the sum of the cross-sectional area (the product of the length and width) of the two central cores 31. The materials of the first magnetic core 1, the second magnetic core 5, and the central core 31 are all metal magnetic powder cores. Metal magnetic powder cores are composite soft magnetic materials made by making powder from metal or alloy soft magnetic materials, and then performing processes such as insulating coating, pressing, and annealing. The alloy soft magnetic materials can be high Bs (saturation magnetic flux) alloys.

[0032] The cross-sections of the first magnetic core 1, the second magnetic core 5, and the central core 31 can all be rectangular with rounded corners. Compared to the circular central core 31, the square central core 31 has a full surface that fits against the housing 6 during winding assembly, resulting in a larger heat dissipation area and a closer linear distance to the water-cooling plate, thus improving heat dissipation. The first frame 2 and the second frame 4 are plastic structural components used for connecting the intermediate winding assembly 3 with the first magnetic core 1 and the second magnetic core 5. They also limit the distance between the intermediate winding assembly 3, the first magnetic core 1, the second magnetic core 5, and the housing, determining a safe distance and serving a positioning function. Soft glue can be used to fix and seal the first frame 2, the second frame 4, and the housing 6 to prevent potting compound from overflowing from between them.

[0033] like Figure 4 As shown, Figure 4 This is an exploded view of an intermediate winding assembly 3, where each central core 31 is wound with a winding 32. (Example) Figure 3As shown, a contoured heat dissipation structure 61 is provided between the two central core magnetic cores 31 inside the housing 6. The contoured heat dissipation structure 61 is in the shape of an inverted triangle to match the shape of the winding. The contoured heat dissipation structure 61 is designed to fit the outer contour of the winding 32 better. The winding 32 can be enameled flat copper wire or flat aluminum wire. The two sides of the inverted triangle formed by the contoured heat dissipation structure 61 can be rounded (the two sides bend towards the center into an arc) to match the outer contour of the winding 32. The contoured heat dissipation structure 61, which protrudes high in the center, fits the recessed design of the surrounding parts of each core and frame. This structure can be omitted for scenarios where heat dissipation requirements are not high.

[0034] like Figure 4 As shown, each central core 31 includes at least two core blocks 313. At least one layer of adhesive 311 is provided between adjacent core blocks 313, between the central core 31 and the first frame 2, and between the central core 31 and the second frame 4. Additionally, at least one air gap gasket 312 is provided between the adhesive 311 and the core blocks 313. The adhesive 311 can be, but is not limited to, a single-component, heat-curing structural bonding epoxy or silicone-based baking adhesive. The core blocks 313 and the air gap gasket 312 are connected as a whole using the adhesive 311. This adhesive has ideal bonding strength and stress resistance at high temperatures, ensuring stable performance of the device under high reliability requirements.

[0035] The material of the air gap gasket 312 can be, but is not limited to, insulating paper with good mechanical strength (such as Nomi paper), ceramic sheet, epoxy board, etc. The thickness is adjusted according to the actual magnetic core block 313, and the size is smaller than the cross-sectional size of the magnetic core block 313, including the length and width.

[0036] Several magnetic core blocks 313 form segmented air gaps in the core. The air gaps are divided into multiple segments with a uniform and reasonable distribution, which reduces coil heating. The segmentation of the air gaps, by dividing a single air gap into multiple smaller air gaps, aims to reduce leakage flux, reduce eddy current effects, improve thermal stability, precisely control inductance, reduce losses, and meet the requirements of miniaturization and high performance.

[0037] The principle of segmenting the air gap (GAP) of the magnetic core is as follows: First, the size of a single air gap (GAP) should not exceed 1 / 2 of the distance d from the winding to the magnetic core block 313 (generally, a single GAP is approximately d / 3); Second, the air gap of the magnetic core should be evenly distributed inside the winding, that is, the size and spacing of the air gaps should be consistent. A reasonable and uniform distribution of the air gaps can effectively reduce the AC loss of the coil and reduce heat generation.

[0038] In some embodiments, in addition to the above-described technical solutions, the width-to-height ratio of the central core 31 of this utility model is 0.5-1. For example, a preferred embodiment is provided where the height of the central core 31 is 40mm and the width is 40mm. Due to the increased width-to-height ratio, this short and wide design uses the increase in width to reduce the height, thereby reducing the overall height of the inductor.

[0039] In some embodiments, in addition to the above-described technical solutions, such as Figure 5 As shown, Figure 5 This is a structural diagram of one side of the first frame 2. At least three first limiting adhesive strips 21 are provided on one side of the first frame 2, and the first magnetic core 1 is installed between the first limiting adhesive strips 21. The material of the first limiting adhesive strips 21 is the same as that of the first frame 2.

[0040] In some embodiments, in addition to the above-described technical solutions, such as Figure 6 As shown, Figure 6 This is a structural diagram of the other side of the first frame 2 and one side of the second frame 4. The upper diagram shows the second frame 4, and the lower diagram shows the first frame 2. Several second limiting strips 41 are provided on the other side of the first frame 2 and one side of the second frame 4. The intermediate winding assembly 3 is installed between the second limiting strips 41. The material of the second limiting strips 41 can be the same as that of the first frame 2 and the second frame 4. The second limiting strips 41 are used to limit the first magnetic core 1 and the second magnetic core 5, and to maintain a safe distance between the first magnetic core 1 and the second magnetic core 5 and the outer shell. Additionally, the first frame 2 and the second frame 4 are each provided with the same number of arc-shaped holes as the central column magnetic core 31. These arc-shaped holes are used to enclose the central column magnetic core 31.

[0041] In some embodiments, in addition to the above-described technical solutions, such as Figure 6 As shown, the second frame 4 is provided with at least two electrical terminals 42, and one end of each winding is welded to one electrical terminal 42. The material of the electrical terminals 42 can be, but is not limited to, copper C1100. The electrical terminals 42 are electrically connected to the windings, and the welding method can be selected according to the wire diameter of the winding conductor. For large wire diameters, electron beam welding is preferred, while for small wire diameters, tin-welded welding can be used. The electrical terminals 42 can be, but is not limited to, fixed to the second frame 4 by screws. In addition, a number of reinforcing ribs 44 can be provided around the electrical terminals 42, where "a number" indicates 1 or more. In the figure, each electrical terminal 42 is provided with 5 triangles. The reinforcing ribs 44 can be, but are not limited to, triangles. The reinforcing ribs 44 provide better support, allowing the electrical terminals 42 to withstand greater torque. In addition, hexagonal screws for fixing the electrical terminals 42 can be screwed into the frame.

[0042] In some embodiments, in addition to the above-described technical solutions, the center core 31 is wrapped with at least one layer of insulating paper. This serves to isolate the windings from the center core 31 and provides insulation.

[0043] In some embodiments, in addition to the above-described technical solutions, such as Figure 7 As shown, Figure 7 This is a top view of the second frame 4. Bosses 43 are provided at both ends of the other side of the second frame 4, and first mounting holes are provided on the bosses 43. Second mounting holes that mate with the first mounting holes are provided on the housing 6. Screws are used to fix the second frame 4 to the housing through the first and second mounting holes, thus determining the relative positions of the second frame 4 and the housing 6. This structural component ensures product installation accuracy and improves product consistency.

[0044] like Figure 2 As shown, the height of the portion 62 of the housing surrounding the second frame is lower than the height of the portion surrounding the first frame 2 and the intermediate winding assembly 3. That is, the portion 62 of the housing surrounding the second frame is lowered, which fits the asymmetrical assembly of the first magnetic core 1, the second magnetic core 5 and the central column magnetic core 31, and reduces the height of the mounting surface. With the help of the boss 43, the inductor is fixed to prevent displacement of the housing, thereby improving the installation accuracy.

[0045] To better demonstrate the beneficial effects of the short and stout design, this utility model provides the following simulation experiments:

[0046] The following is a comparison of thermal simulation results before and after optimization of the 215KW inductor solution. Before optimization, the dimensions of the core 31 were 55 (height) * 28 (width) mm, the finished product height was 84 mm, and the maximum temperature was approximately 135℃. After optimization, the dimensions of the core 31 were 40 (height) * 40 (width) mm, the finished product height was 70 mm, and the maximum temperature was approximately 112℃. The product temperature rise decreased by approximately 23℃, and the heat dissipation efficiency was significantly improved. This reduction in temperature rise can also be used to reduce the copper wire diameter, thereby reducing the amount of copper wire used and lowering costs. Based on thermal simulation experience with high and low inductors, the height of the inductor is inversely proportional to the thermal conductivity distance of the water-cooled plate; that is, the smaller the inductor height, the shorter the thermal conductivity distance with the water-cooled plate, and the better the heat dissipation effect.

[0047] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Under the concept of this utility model, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of this utility model as described above. For the sake of brevity, they are not provided in detail. Although the present utility model 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. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A high-power inductor, characterized in that, It includes a first magnetic core, a first frame, an intermediate winding assembly, a second frame, a second magnetic core, and a housing; The first magnetic core is mounted on one side of the first frame, the intermediate winding assembly is mounted between the other side of the first frame and one side of the second frame, and the second magnetic core is mounted on the other side of the second frame, forming a magnetic core assembly; the magnetic core assembly is mounted in the housing. The intermediate winding assembly includes at least two central cores, each of which is recessed relative to the first and second cores to form a groove.

2. The inductor according to claim 1, characterized in that, Each of the central cores is wound with a winding; a contoured heat dissipation structure is provided between the two central cores inside the housing, and the contoured heat dissipation structure is in the shape of an inverted triangle in conjunction with the winding.

3. The inductor according to claim 1, characterized in that, Each of the central cores includes at least two core blocks, and at least one layer of adhesive is provided between two adjacent core blocks, between the central core and the first frame, and between the central core and the second frame.

4. The inductor according to claim 1, characterized in that, The width-to-height ratio of the central core is 0.5-1.

5. The inductor according to any one of claims 1-4, characterized in that, At least three first limiting rubber strips are provided on one side of the first skeleton, and the first magnetic core is installed between the first limiting rubber strips.

6. The inductor according to any one of claims 1-4, characterized in that, A plurality of second limiting rubber strips are provided on the other side of the first frame and on one side of the second frame, and the intermediate winding assembly is installed between the second limiting rubber strips.

7. The inductor according to any one of claims 2-4, characterized in that, The second frame is provided with at least two electrical terminals, and one end of each winding is welded to one of the electrical terminals.

8. The inductor according to any one of claims 1-4, characterized in that, The central core is wrapped with at least one layer of insulating paper.

9. The inductor according to any one of claims 1-4, characterized in that, The second frame has bosses at both ends on the other side, and a first mounting hole is provided on the bosses. The housing has a second mounting hole that mates with the first mounting hole.

10. The inductor according to any one of claims 1-4, characterized in that, The portion of the housing surrounding the second frame is lower in height than the portion surrounding the first frame and the intermediate winding assembly.

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