A dual air gap inductor

Abstract

The utility model relates to the field of inductor, concretely is a kind of double air gap inductor, including coil, wire frame and two magnetic cores, coil is wound on wire frame, two magnetic cores form a closed structure and coil is installed in closed structure, at least one magnetic core is provided with convex protrusion of convexity, protrusion includes high surface and low surface, high surface and low surface are all provided with air gap.The product changes the conventional plane air gap, optimizes the air gap structure of magnetic core, adopts the mode of upper and lower double air gap, so that it can present different inductance at high and low current;Protrusion has two air gaps of upper and lower, the small air gap of a small area on the top, the large air gap of large area below, the small air gap on the top, so that there is a high inductance, for small current maintenance work, the large air gap below, so that large current works in safety zone, does not reach magnetic saturation, improves the magnetic flux distribution of traditional plane air gap inductor, reduces loss and inhibits electromagnetic interference.

Description

Technical Field

[0001] This utility model relates to the field of inductors, specifically a dual-air-gap inductor. Background Technology

[0002] In current electronic power systems, inductors serve as core energy storage and filtering components, and their performance directly affects the system's power conversion efficiency, size, cost, and electromagnetic compatibility. In applications requiring large energy storage or handling of large DC bias currents (such as power factor positive inductors, output filter inductors, and energy storage inductors in DC-DC converters), an air gap is typically introduced into the magnetic core. The purpose of introducing the air gap is to adjust the inductance and prevent magnetic saturation. Traditional inductors typically incorporate a single-plane air gap in the core column to suppress magnetic saturation and increase energy storage capacity. However, the inductance of this structure decreases linearly with increasing current, leading to insufficient inductance under light loads, resulting in increased ripple and low efficiency, thus limiting system efficiency optimization over a wide current range. Especially in high-power power supplies, this linear attenuation characteristic has become a bottleneck for improving overall system efficiency. A previous patent (CN202310921753) established a mathematical model of a stepped air gap using calculus partitioning and magnetoresistive integration algorithms. However, this is merely a simulation design method and does not address structural breakthroughs such as the step height difference or transition surface, nor does it involve any physical structural innovation. Other patents and documents divide the large air gap into multiple layers of air gap plates to reduce losses, but each air gap plate has the same thickness and no height difference, which fails to solve the nonlinear control requirements. Utility Model Content

[0003] To achieve the above objectives, the present invention aims to provide a dual air-gap inductor that can solve the problems existing in the prior art. The present invention provides the following technical solution:

[0004] A dual-air-gap inductor includes a coil, a wire frame, and two magnetic cores. The coil is wound on the wire frame, and the two magnetic cores form a closed structure, with the coil installed inside the closed structure. At least one magnetic core has a convex protrusion, which includes a high surface and a low surface, both of which have air gaps. The protrusion can be made by mold pressing or by subsequent grinding. The magnetic core covers a large area of ​​the coil, providing good shielding and facilitating heat dissipation of the coil.

[0005] As a further embodiment of this utility model, the width of the protrusion is 1.5-8.5mm, and the width can be adjusted accordingly according to the requirements of the working application.

[0006] As a further embodiment of this utility model, the protrusion can be circular, square, elliptical, or other combined shapes, selected according to the actual situation.

[0007] As a further embodiment of this invention: the area of ​​the air gap on the higher surface is smaller than the area of ​​the air gap on the lower surface. The smaller air gap on the higher surface results in a high inductance, which is used to maintain operation when the current is small. The larger air gap on the lower surface allows the device to operate in a safe area when the current is large, preventing magnetic saturation.

[0008] As a further embodiment of this invention, two or four grooves are provided around the magnetic core to facilitate heat dissipation.

[0009] As a further embodiment of this utility model: when the number of grooves is four, the four grooves are evenly arranged on the upper side, lower side, left side and right side of the magnetic core; when the number of grooves is two, the two grooves are symmetrically arranged on opposite sides of the magnetic core, so that heat dissipation is uniform.

[0010] As a further embodiment of this utility model: a reinforcing rib is provided at the lower edge of the hole in the wire frame to make the wire frame firm and non-deformable, so that the pin spacing of the wire frame remains unchanged, making it easy to install on the circuit board.

[0011] As a further embodiment of this invention: the reinforcing rib is trapezoidal in shape. The trapezoidal reinforcing rib itself can reduce stress concentration and improve the durability of the structure through its smooth transition surface. The shape of the trapezoidal reinforcing rib can better adapt to certain specific structural requirements, provide better support and stability, and also save material consumption, reduce weight, and lower costs.

[0012] Compared with the prior art, the beneficial effects of this utility model are:

[0013] This product changes the conventional planar air gap and optimizes the air gap structure of the magnetic core. It adopts a double air gap design to achieve nonlinear adaptive adjustment of the inductance, improve magnetic flux distribution, reduce losses and suppress electromagnetic interference, thus exhibiting different inductance values ​​at different currents. The protrusion has two air gaps, one small air gap on top and one large air gap on the bottom. The small air gap on top provides a high inductance for operation at low currents, while the large air gap on the bottom ensures safe operation at high currents, preventing magnetic saturation. Attached Figure Description

[0014] Figure 1 This is an exploded view of the dual-air-gap inductor in an embodiment of this utility model.

[0015] Figure 2 This is a schematic diagram of the wire frame structure in a double air gap inductor.

[0016] Figure 3 This is a schematic diagram of the magnetic core structure in a dual-air-gap inductor.

[0017] Figure 4 This is a cross-sectional view of a dual-gap inductor with only one magnetic core using a dual-gap design.

[0018] Figure 5 This is a cross-sectional view of a dual-gap inductor where both magnetic cores employ dual air gaps.

[0019] In the diagram: 1-Magnetic core; 2-Wire frame; 3-Coil; 4-Protrusion; 5-Groove; 6-Reinforcing rib. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] The specific implementation of this utility model will be described in detail below with reference to specific embodiments.

[0022] Example 1, please refer to Figure 1 and Figure 4 This utility model provides a dual air gap inductor, including a coil 3, a wire frame 2, and two magnetic cores 1. The coil 3 is wound on the wire frame 2, and the two magnetic cores 1 form a closed structure and the coil 3 is installed in the closed structure. A convex protrusion 4 is provided in one of the magnetic cores 1. The protrusion 4 includes a high surface and a low surface, and air gaps are provided on both the high surface and the low surface. The protrusion 4 can be made by mold pressing or by post-grinding. The magnetic core 1 covers a large area of ​​the coil 3, which has a good shielding effect and facilitates the heat dissipation of the coil 3.

[0023] Example 2, please refer to Figure 1 and Figure 4 This utility model provides a dual air gap inductor, including a coil 3, a wire frame 2, and two magnetic cores 1. The coil 3 is wound on the wire frame 2, and the two magnetic cores 1 form a closed structure and the coil 3 is installed in the closed structure. A convex protrusion 4 is provided in one of the magnetic cores 1. The protrusion 4 includes a high surface and a low surface, and air gaps are provided on both the high surface and the low surface. The protrusion 4 can be made by mold pressing or by post-grinding. The magnetic core 1 covers a large area of ​​the coil 3, which has a good shielding effect and facilitates the heat dissipation of the coil 3.

[0024] Furthermore, the width of protrusion 4 is 1.5-8.5mm. The width can be adjusted accordingly based on the requirements of the work application to suit different work scenarios.

[0025] Furthermore, protrusion 4 can be round, square, oval, or other combined shapes, which can be selected according to the actual situation, and has a wide range of applications.

[0026] Example 3, please refer to Figure 1and Figure 5 This utility model provides a dual air gap inductor, including a coil 3, a wire frame 2, and two magnetic cores 1. The coil 3 is wound on the wire frame 2, and the two magnetic cores 1 form a closed structure and the coil 3 is installed in the closed structure. Each of the two magnetic cores 1 is provided with a convex protrusion 4, which includes a high surface and a low surface. Both the high surface and the low surface are provided with air gaps. The protrusion 4 can be made by mold pressing or by post-grinding. The magnetic core 1 covers a large area of ​​the coil 3, which has a good shielding effect and facilitates the heat dissipation of the coil 3.

[0027] Furthermore, the area of ​​the air gap on the higher surface is smaller than that on the lower surface. The smaller air gap on the higher surface results in a high inductance, which is used to maintain operation at low currents. The larger air gap on the lower surface allows operation in a safe area at high currents, preventing magnetic saturation.

[0028] Example 4, please refer to Figure 1 , Figure 3 and Figure 4 This utility model provides a dual air gap inductor, including a coil 3, a wire frame 2, and two magnetic cores 1. The coil 3 is wound on the wire frame 2, and the two magnetic cores 1 form a closed structure and the coil 3 is installed in the closed structure. A convex protrusion 4 is provided in one of the magnetic cores 1. The protrusion 4 includes a high surface and a low surface, and air gaps are provided on both the high surface and the low surface. The protrusion 4 can be made by mold pressing or by post-grinding. The magnetic core 1 covers a large area of ​​the coil 3, which has a good shielding effect and facilitates the heat dissipation of the coil 3.

[0029] Furthermore, four grooves 5 are provided around the magnetic core 1 to facilitate heat dissipation.

[0030] Furthermore, the four grooves 5 are evenly arranged on the upper, lower, left and right sides of the magnetic core 1, which improves the heat dissipation uniformity of the magnetic core and makes the coil 3 work for a longer period of time.

[0031] Example 5, please refer to Figure 1 , Figure 2 and Figure 5 This utility model provides a dual air gap inductor, including a coil 3, a wire frame 2, and two magnetic cores 1. The coil 3 is wound on the wire frame 2, and the two magnetic cores 1 form a closed structure and the coil 3 is installed in the closed structure. Each of the two magnetic cores 1 is provided with a convex protrusion 4, which includes a high surface and a low surface. Both the high surface and the low surface are provided with air gaps. The protrusion 4 can be made by mold pressing or by post-grinding. The magnetic core 1 covers a large area of ​​the coil 3, which has a good shielding effect and facilitates the heat dissipation of the coil 3.

[0032] Furthermore, a reinforcing rib 6 is provided at the lower edge of the hole in the wire frame 2 to make the wire frame 2 firm and non-deformable, so that the pin spacing of the wire frame 2 remains unchanged, making it easy to install on the circuit board.

[0033] Furthermore, the shape of the reinforcing rib 6 is trapezoidal. The trapezoidal reinforcing rib 6 itself can reduce stress concentration and improve the durability of the structure through its smooth transition surface. The shape of the trapezoidal reinforcing rib 6 can better adapt to certain specific structural requirements and provide better support and stability.

[0034] It should be noted that, in this utility model, unless otherwise explicitly specified and limited, the terms "fixed," "set," etc., should be interpreted broadly. For example, they can refer to welded connections, bolted connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0035] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A dual air-gap inductor, comprising a coil, a wire frame, and two magnetic cores, wherein the coil is wound on the wire frame, the two magnetic cores form a closed structure, and the coil is mounted within the closed structure, characterized in that, At least one magnetic core has a convex protrusion, which includes a high surface and a low surface, and both the high surface and the low surface have an air gap.

2. The dual air-gap inductor according to claim 1, characterized in that, The width of the protrusion is 1.5-8.5mm.

3. The dual air-gap inductor according to claim 1 or 2, characterized in that, The protrusion can be circular, square, oval, or any combination of the three shapes.

4. The dual air-gap inductor according to claim 1, characterized in that, The area of ​​the air gap on the higher surface is smaller than the area of ​​the air gap on the lower surface.

5. The dual air-gap inductor according to claim 1 or 4, characterized in that, The magnetic core is provided with grooves around its perimeter, and the number of grooves is two or four.

6. The dual air-gap inductor according to claim 5, characterized in that, When the number of grooves is four, the four grooves are evenly distributed on the upper, lower, left, and right sides of the magnetic core.

7. The dual air-gap inductor according to claim 1, characterized in that, The lower edge of the hole in the wire frame is provided with a reinforcing rib.

8. The dual air-gap inductor according to claim 7, characterized in that, The reinforcing rib is trapezoidal in shape.

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