Hybrid magnetic circuit potted inductor
By combining a hybrid magnetic circuit structure with a magnetic powder core and a C-type amorphous magnetic core, and using thermally conductive silicone potting, the problems of low efficiency and high cost of inductors at high frequencies are solved, achieving miniaturization, low noise and high performance of inductors.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ANHUI NENGQI ELECTRIC TECH CO LTD
- Filing Date
- 2025-06-04
- Publication Date
- 2026-06-16
AI Technical Summary
Existing inductors are inefficient at high frequencies, and amorphous magnetic cores are expensive and difficult to manufacture, leading to increased inductor production costs and severe electromagnetic interference.
It adopts a hybrid magnetic circuit structure, combining a magnetic powder core and a C-type amorphous magnetic core, and uses thermally conductive silicone potting to form a semi-enclosed space. The coil is wound on the outside of the central column and isolated by an insulation structure to enhance heat dissipation and electromagnetic shielding.
It reduces inductor noise, decreases inductor size, lowers production costs, increases permeability and inductance, enhances heat dissipation, and is suitable for high-frequency stability, meeting both cost and performance requirements.
Smart Images
Figure CN224366639U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of inductor technology, and in particular to a hybrid magnetic circuit potted inductor. Background Technology
[0002] In recent years, to achieve the goals of "carbon peaking and carbon neutrality," the photovoltaic power generation industry has become one of the fastest-growing new energy industries. With the widespread use of solar photovoltaic inverters, charging piles, UPS systems, and energy storage devices, the demand for inductors is increasing, and the required operating frequency and inductance are also growing. However, in circuits, increased electromagnetic interference from various components leads to low inductor efficiency and significant waste. To improve permeability and reduce losses, amorphous magnetic cores have emerged. However, amorphous magnetic cores are expensive, with rising raw material prices and labor costs. Furthermore, the manufacturing process for amorphous magnetic cores is less mature than that for magnetic powder cores, making it difficult to produce various block-shaped cores with rounded corners. Existing amorphous magnetic core designs increase copper wire usage, significantly increasing inductor production costs and placing enormous cost pressure on the photovoltaic power generation industry. Utility Model Content
[0003] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a hybrid magnetic circuit potted inductor.
[0004] The solution to the technical problem of this utility model is:
[0005] A hybrid magnetic circuit potted inductor, comprising:
[0006] A hybrid magnetic circuit includes a magnetic powder core and a C-type amorphous magnetic core. The magnetic powder core includes an upper yoke, a lower yoke, and a central pillar. The front and rear ends of the central pillar are connected to the upper yoke and the lower yoke, respectively. The C-type amorphous magnetic core is located outside the central pillar and between the upper yoke and the lower yoke. A potting space is formed between the central pillar and the amorphous magnetic core. The opening of the C-type amorphous magnetic core communicates with the potting space.
[0007] A coil, the coil being wound around the outside of the central column, the end of the coil extending out of the potting space from the opening of the C-shaped amorphous magnetic core;
[0008] An insulating structure is provided between the coil and the hybrid magnetic circuit to isolate the coil and the hybrid magnetic circuit;
[0009] Thermally conductive silicone, wherein the thermally conductive silicone is encapsulated within the encapsulation space.
[0010] This invention has at least the following beneficial effects: the C-type amorphous magnetic core and the magnetic powder core are combined to form a hybrid magnetic circuit, and then the thermally conductive silicone is potted to not only enhance the heat dissipation of the coil, but also reduce the volume of the inductor. Moreover, the C-type amorphous magnetic core can also play an electromagnetic shielding role, reducing the noise of the inductor during use. It is also suitable for existing amorphous magnetic core production processes. When combined with the high-frequency stability magnetic powder core, it can balance production costs and performance requirements.
[0011] As a further improvement to the above technical solution, the insulation structure includes two first insulating frames, which respectively cover the front end and the rear end of the coil.
[0012] As a further improvement to the above technical solution, the insulation structure also includes insulating paper, which covers the outer periphery of the central column and is located between the coil and the central column.
[0013] As a further improvement to the above technical solution, the insulation structure further includes a ceramic sheet, the front end of which is connected to the upper yoke, the rear end of which is connected to the lower yoke, and the ceramic sheet is disposed between the C-type amorphous magnetic core and the coil.
[0014] As a further improvement to the above technical solution, an air gap is provided between the upper yoke and the C-type amorphous magnetic core.
[0015] As a further improvement to the above technical solution, the hybrid magnetic circuit, the coil, the insulating structure, and the thermally conductive silicone jointly constitute an inductor structure. The hybrid magnetic circuit potted inductor also includes a base, which is located on the lower side of the inductor structure. The opening of the C-shaped amorphous magnetic core faces downward. The base has a through hole, and the end of the coil passes through the through hole.
[0016] As a further improvement to the above technical solution, baffles are provided at the front and rear ends of the base, and the inductor structure is located between the two baffles.
[0017] As a further improvement to the above technical solution, the insulation structure further includes a second insulation skeleton, which includes a front skeleton and a rear skeleton. The front skeleton covers the upper surface of the upper yoke, and the rear skeleton covers the upper surface of the lower yoke.
[0018] As a further improvement to the above technical solution, the second insulating frame also includes an upper frame, the front and rear ends of which are connected to the front frame and the rear frame respectively, and the upper frame is located above the C-shaped amorphous magnetic core.
[0019] As a further improvement to the above technical solution, the inductor structure is provided in multiple ways, and the multiple inductor structures are respectively mounted on the base. Attached Figure Description
[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly explained below. Obviously, the described drawings are only a part of the embodiments of this utility model, and not all of them. Those skilled in the art can obtain other design schemes and drawings based on these drawings without creative effort.
[0021] Figure 1 This is a schematic diagram of the inductor structure according to an embodiment of the present invention;
[0022] Figure 2 This is a schematic diagram of the overall structure of the hybrid magnetic circuit potted inductor according to an embodiment of the present invention;
[0023] Figure 3 This is an exploded structural diagram of the inductor structure according to an embodiment of the present invention;
[0024] Figure 4 This is a schematic diagram of the hybrid magnetic circuit according to an embodiment of the present invention;
[0025] Figure 5 This is a bottom view of the inductor structure of this utility model embodiment without being potted with thermally conductive silicone.
[0026] Figure 6 yes Figure 5 A cross-sectional view along the AA direction.
[0027] Reference numerals: 100, C-type amorphous magnetic core; 110, air gap; 200, magnetic powder core; 210, upper yoke; 220, lower yoke; 230, central column; 300, coil; 400, thermally conductive silicone; 500, first insulating frame; 600, ceramic sheet; 700, insulating paper; 800, base; 810, baffle; 900, second insulating frame; 910, front frame; 920, rear frame; 930, upper frame. Detailed Implementation
[0028] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.
[0029] In the description of this utility model, the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0030] In the description of this utility model, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. If "first" or "second" is used in the description, it is only for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.
[0031] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.
[0032] Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are all within the scope of protection of this utility model. The various technical features of this utility model can be combined interactively without contradicting each other.
[0033] Reference Figure 1 , Figure 2 and Figure 3 This utility model embodiment proposes a hybrid magnetic circuit potted inductor, which uses a hybrid magnetic circuit to balance production costs and performance issues, reducing production costs while improving magnetic permeability and reducing losses.
[0034] The hybrid magnetic circuit potted inductor of this embodiment includes a hybrid magnetic circuit, a coil 300, an insulating structure, and thermally conductive silicone 400. Reference is made to... Figure 4 and Figure 5 The hybrid magnetic circuit includes a magnetic powder core 200 and a C-type amorphous magnetic core 100. The magnetic powder core 200 includes an upper yoke 210, a lower yoke 220, and a central pillar 230. The front end of the central pillar 230 is connected to the upper yoke 210, and the rear end of the central pillar 230 is connected to the lower yoke 220. The C-type amorphous magnetic core 100 is disposed outside the central pillar 230 and located between the upper yoke 210 and the lower yoke 220. The central pillar 230 and the decomposed magnetic core diameter form a potting space, and the opening of the C-type amorphous magnetic core 100 is connected to the potting space.
[0035] Reference Figure 5 and Figure 6 The coil 300 is wound around the outside of the central post 230 and located inside the C-type amorphous magnetic core 100. Both ends of the coil 300 extend out of the potting space through openings in the C-type amorphous magnetic core 100 for easy connection to external devices. An insulating structure is provided between the coil 300 and the hybrid magnetic circuit, isolating them and achieving insulation. Thermally conductive silicone 400 is potted within the potting space to enhance heat dissipation, thereby improving the performance of the hybrid magnetic circuit potted inductor.
[0036] It is understandable that in the hybrid magnetic circuit of this embodiment, the high strength, high toughness, and low loss characteristics of amorphous materials are used to create a C-shaped structure. Then, thermally conductive silicone 400 is potted to replace the traditional solution of putting the inductor into an aluminum shell and then potting thermally conductive silicone 400. This not only enhances the heat dissipation effect of the coil 300, but also reduces the size of the inductor. Moreover, the C-shaped amorphous magnetic core 100 can also play an electromagnetic shielding role, reducing the noise of the inductor during use.
[0037] Understandably, amorphous materials are more easily magnetized under the influence of a magnetic field, enabling them to conduct magnetic field lines more efficiently. This results in a higher effective permeability of the magnetic circuit compared to a fully powder-core design, thereby increasing the inductance of the inductor. The higher the effective permeability, the greater the inductance value.
[0038] However, considering the current limitations in amorphous material preparation technology compared to the mature manufacturing process of magnetic powder core 200, it is difficult to fabricate various blocky magnetic cores with rounded corners. Using all-amorphous materials to fabricate the magnetic circuit would increase the amount of copper wire used in the design, thus raising product costs. Given the better stability and lower production cost of magnetic powder core 200, an optimized magnetic circuit structure formed by combining magnetic powder core 200 and C-type amorphous magnetic core 100 can improve circuit stability, reduce production costs, and also increase effective permeability.
[0039] In addition, the semi-enclosed potting space formed by the C-type amorphous magnetic core 100 and the magnetic powder core 200, and the opening of the C-type amorphous magnetic core 100 are conducive to the potting of the thermally conductive silicone 400, making the production process simpler and easier to operate.
[0040] In this embodiment, the coil 300 is wound on the outside of the central column 230 using a flat wire vertical winding method. The two ends of the coil 300 extend through the opening of the C-shaped amorphous magnetic core 100, which is conducive to automation, helps to control the consistency of product size, and meets the design requirements.
[0041] In some embodiments, refer to Figure 3 , Figure 5 and Figure 6The insulation structure includes two first insulating frames 500, which respectively cover the front end and the rear end of the coil 300. It can be understood that the first insulating frame 500 located at the front end of the coil 300 is used to isolate the coil 300 and the upper yoke 210, and the first insulating frame 500 located at the rear end of the coil 300 is used to isolate the coil 300 and the lower yoke 220.
[0042] In this embodiment, the first insulating frame 500 is provided with a slot, and the slot openings of the two first insulating frames 500 are arranged facing each other. The front and rear ends of the coil 300 are respectively snapped into the slots of the two first insulating frames 500. The first insulating frame 500 is provided with a connecting hole, which passes through the front and rear end faces of the first insulating frame 500. The central column 230 passes through the connecting hole and is connected to the upper yoke 210 or the lower yoke 220.
[0043] Understandably, the slot design can limit the movement of coil 300 and maintain a safe distance between the outer periphery of coil 300 and C-type amorphous magnetic core 100.
[0044] In some embodiments, refer to Figure 3 and Figure 6 The insulation structure also includes insulating paper 700, which covers the outer periphery of the central post 230 and is located between the coil 300 and the central post 230, and can provide insulation and isolation between the coil 300 and the central post 230.
[0045] In some embodiments, refer to Figure 3 and Figure 6 The insulation structure also includes a ceramic sheet 600, which extends in the front-to-back direction. The front end of the ceramic sheet 600 is connected to the upper yoke 210, and the rear end of the ceramic sheet 600 is connected to the lower yoke 220. The ceramic sheet 600 is disposed between the C-type amorphous magnetic core 100 and the coil 300, and is located outside the first insulating frame 500.
[0046] It is understood that the ceramic sheet 600 can effectively isolate the coil 300 and the C-type amorphous magnetic core 100, achieving an insulation effect. In this embodiment, there are three ceramic sheets 600 arranged around the outer periphery of the coil 300, located on the left, right, and top sides of the coil 300 respectively. The ends of the coil 300 extend downwards, and there is a heat dissipation space between adjacent ceramic sheets 600. When the thermally conductive silicone 400 is potted, it can be poured into the spaces between adjacent ceramic sheets 600, improving the heat dissipation effect while ensuring effective insulation.
[0047] In some embodiments, refer to Figure 4 An air gap 110 is provided between the upper yoke 210 and the C-type amorphous magnetic core 100. The inductance can be controlled by adjusting the size of the air gap 110, thereby increasing the saturation current and reducing the residual magnetism, thus playing a role in energy storage.
[0048] It is understandable that the hybrid magnetic circuit, coil 300, insulation structure, and thermally conductive silicone 400 together constitute the inductor structure, as shown in the reference. Figure 2 In some embodiments, the hybrid magnetic circuit potted inductor also includes a base 800, which is disposed on the lower side of the inductor structure. The opening of the C-type amorphous magnetic core 100 is disposed downward. The base 800 is provided with a through hole, through which the end of the coil 300 passes.
[0049] Understandably, each coil 300 has two ends, and the number and position of the through holes correspond to the number of ends of the coil 300. This arrangement allows the ends of the coil 300 to be led out through the through holes of the base 800 to form a plug-in structure, making it more convenient for customers to install and use.
[0050] In this embodiment, the base 800 is made of epoxy board. Epoxy board has good mechanical and dielectric properties, good heat and moisture resistance, and good machinability.
[0051] In some embodiments, baffles 810 are respectively provided at the front and rear ends of the base 800, and the inductor structure is installed between the two baffles 810. The baffles 810 can provide space for the installation of the inductor structure and protect the front and rear ends of the inductor structure, ensuring a safe distance between the inductor structure and peripheral components.
[0052] In some embodiments, refer to Figure 2 The insulation structure also includes a second insulating frame 900, which is disposed on the outer side of the hybrid magnetic circuit. Specifically, the second insulating frame 900 includes a front frame 910 and a rear frame 920. The front frame 910 covers the upper surface of the upper yoke 210, and the rear frame 920 covers the upper surface of the lower yoke 220. It can be understood that both the front frame 910 and the rear frame 920 are contoured frames, and the upper surfaces of the upper yoke 210 and the lower yoke 220 are both curved surfaces. The shapes of the front frame 910 and the rear frame 920 follow the orientation of the upper surfaces of the upper yoke 210 and the lower yoke 220.
[0053] Understandably, the front frame 910 can isolate the upper surface of the upper yoke 210 from the peripheral components to ensure a safe distance; the rear frame 920 can isolate the upper surface of the lower yoke 220 from the peripheral components to ensure a safe distance.
[0054] In some embodiments, the second insulating frame 900 further includes an upper frame 930, the front end of which is connected to the front frame 910 and the rear end of which is connected to the rear frame 920. The upper frame 930 is disposed above the C-type amorphous magnetic core 100 and can isolate and protect the upper surface of the C-type amorphous magnetic core 100 to ensure a safe distance between the C-type amorphous magnetic core 100 and peripheral components.
[0055] It is understood that by setting the second insulating frame 900, it can be ensured that all other components of the customer's entire machine meet the safety specifications for insulation from the hybrid magnetic circuit potted inductor of this embodiment. In this embodiment, the second insulating frame 900 is set on the outside of the hybrid magnetic circuit by adhesive bonding.
[0056] In some embodiments, multiple inductor structures are provided, and each inductor structure is mounted on the base 800. (Refer to...) Figure 2 In this embodiment, three identical inductor structures are provided, arranged in a left-right direction. It is understood that installing multiple inductor structures on the same base 800 satisfies the installation quantity requirements while saving inductor space, making it more convenient for users.
[0057] In this embodiment, the second insulating frames 900 of adjacent inductor structures are interconnected. The front frame 910 of each inductor structure is integrally formed, and the rear frame 920 of each inductor structure is integrally formed. The relative positions of each inductor structure can also be positioned by the second insulating frames 900.
[0058] This embodiment of the hybrid magnetic circuit potted inductor uses a flat wire vertical winding method for the coil 300, which facilitates assembly. Considering both cost and performance, it employs a high-strength, high-hardness, high-saturation magnetic induction intensity, and low-loss C-type amorphous magnetic core 100, combined with a low-loss, high-frequency stability magnetic powder core 200 to form a hybrid magnetic circuit. Compared to the traditional all-powder core inductor structure design, the hybrid magnetic circuit potted inductor of this embodiment occupies significantly less space, meeting both product structural size requirements and electrical performance requirements. The overall inductor loss is also lower than that of an all-powder core inductor, and the thermally conductive silicone 400 potting solution improves the inductor's heat dissipation effect.
[0059] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.
Claims
1. A hybrid magnetic circuit potted inductor, characterized in that, include: A hybrid magnetic circuit includes a magnetic powder core and a C-type amorphous magnetic core. The magnetic powder core includes an upper yoke, a lower yoke, and a central pillar. The front and rear ends of the central pillar are connected to the upper yoke and the lower yoke, respectively. The C-type amorphous magnetic core is located outside the central pillar and between the upper yoke and the lower yoke. A potting space is formed between the central pillar and the amorphous magnetic core. The opening of the C-type amorphous magnetic core communicates with the potting space. A coil, the coil being wound around the outside of the central column, the end of the coil extending out of the potting space from the opening of the C-shaped amorphous magnetic core; An insulating structure is provided between the coil and the hybrid magnetic circuit to isolate the coil and the hybrid magnetic circuit; Thermally conductive silicone, wherein the thermally conductive silicone is encapsulated within the encapsulation space.
2. The hybrid magnetic circuit potted inductor according to claim 1, characterized in that, The insulation structure includes two first insulating frames, which respectively cover the front end and the rear end of the coil.
3. The hybrid magnetic circuit potted inductor according to claim 2, characterized in that, The insulation structure also includes insulating paper, which covers the outer periphery of the central column and is located between the coil and the central column.
4. The hybrid magnetic circuit potted inductor according to claim 2, characterized in that, The insulating structure also includes a ceramic sheet, the front end of which is connected to the upper yoke, and the rear end of which is connected to the lower yoke. The ceramic sheet is disposed between the C-shaped amorphous magnetic core and the coil.
5. The hybrid magnetic circuit potted inductor according to claim 1, characterized in that, An air gap is provided between the upper yoke and the C-type amorphous magnetic core.
6. The hybrid magnetic circuit potted inductor according to claim 1, characterized in that, The hybrid magnetic circuit, the coil, the insulating structure, and the thermally conductive silicone jointly constitute the inductor structure. The hybrid magnetic circuit potted inductor also includes a base, which is located on the lower side of the inductor structure. The opening of the C-shaped amorphous magnetic core faces downward. The base has a through hole, and the end of the coil passes through the through hole.
7. The hybrid magnetic circuit potted inductor according to claim 6, characterized in that, The base is provided with baffles at its front and rear ends, and the inductor structure is located between the two baffles.
8. The hybrid magnetic circuit potted inductor according to claim 6, characterized in that, The insulation structure further includes a second insulation skeleton, which includes a front skeleton and a rear skeleton. The front skeleton covers the upper surface of the upper yoke, and the rear skeleton covers the upper surface of the lower yoke.
9. The hybrid magnetic circuit potted inductor according to claim 8, characterized in that, The second insulating frame also includes an upper frame, the front and rear ends of which are connected to the front frame and the rear frame, respectively, and the upper frame is located above the C-shaped amorphous magnetic core.
10. The hybrid magnetic circuit potted inductor according to claim 8, characterized in that, The inductor structure is provided in multiple ways, and the multiple inductor structures are respectively mounted on the base.