High-integration encapsulated combined inductor with die-cast aluminum shell
By introducing a positioning structure of die-cast aluminum shell and inner support into the potted composite inductor, the problem of inductor unit potting misalignment is solved, achieving high-precision positioning and insulation isolation of the inductor, and improving the reliability and lifespan of the product.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN ZHONGLIAO TECH CO LTD
- Filing Date
- 2025-06-11
- Publication Date
- 2026-07-07
AI Technical Summary
Existing potted composite inductors lack effective support structures in their structural design, which makes the inductor units prone to positional shifts during the potting process. This affects the consistency of electrical parameters and the reliability of the equipment, and can also lead to problems such as loose solder joints and insulation failure.
The highly integrated potted composite inductor uses a die-cast aluminum shell, including a die-cast aluminum shell, an inner support, and an inductor unit. The positioning structure of the inner support and the die-cast aluminum shell, along with the filling of thermally conductive silicone, ensures precise positioning and insulation of the inductor unit. Combined with the heat sink design, the protection level and service life of the product are improved.
It achieves precise positioning of the inductor unit, reduces electrical parameter deviation, improves product consistency and reliability, meets the requirements of high-precision circuit design, and maintains the stability and protection performance of the inductor unit in harsh environments.
Smart Images
Figure CN224472277U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of combined inductors, in particular to a die-cast aluminum shell for a highly integrated encapsulated combined inductor. Background Art
[0002] In the field of electronic components, combined inductors, as important passive components, are widely used in the circuits of various electronic devices. The encapsulated combined inductor is encapsulated with inductance units through an encapsulation process to achieve functions such as protection and insulation, improving the stability and reliability of the product.
[0003] There are deficiencies in the structural design of existing encapsulated combined inductors, and no effective support structure is provided inside. During the encapsulation process, due to the impact force and gravity generated by the flow of the encapsulation material, the inductance units are prone to position offset. This offset will cause a series of adverse effects: on the one hand, inaccurate positions of the inductance units will cause electrical parameters such as the inductance value and parasitic capacitance of the inductor to deviate from the design standards, affecting the realization of functions such as filtering and energy storage in the circuit and reducing the overall performance of the electronic device; on the other hand, the offset inductance units may have poor contact with surrounding components or generate stress concentration, and problems such as solder joint loosening and insulation failure are likely to occur under the vibration and temperature cycling of the device during long-term operation, shortening the service life of the inductor and even the entire electronic device, and increasing the after-sales maintenance cost and failure risk of the product. Therefore, it is urgent to optimize the structure of the encapsulated combined inductor to solve the problem of encapsulation offset of the inductance units and improve the product quality and reliability. Content of the Utility Model
[0004] Aiming at the deficiencies of the existing technology, the purpose of the utility model is to provide a die-cast aluminum shell for a highly integrated encapsulated combined inductor to solve the above problems.
[0005] To achieve the above purpose, the technical solution adopted by the utility model is: a die-cast aluminum shell for a highly integrated encapsulated combined inductor, including a die-cast aluminum shell, an inner support, and multiple inductance units. Among them, a plurality of partition plates are formed at intervals along the length direction of the inner cavity of the die-cast aluminum shell to form a plurality of unit chambers for assembling each inductance unit. A sunken positioning groove hole is provided at the bottom surface of each unit chamber, and a plurality of avoidance gaps are formed by recessing at the top of the partition plate; the inner support is made by die-casting aluminum, and the inner support includes a plurality of unit shells. A structural connection frame is formed and connected between adjacent unit shells. The structural connection frame is arranged in an inverted "U" shape. A positioning protrusion is formed at the bottom surface of the unit shell. During assembly, each unit shell of the inner support is respectively embedded in the corresponding unit chamber, and its positioning protrusion is clamped in the corresponding positioning groove hole. At the same time, the tops of each structural connection frame are respectively clamped in the corresponding avoidance gaps to keep the top edge of the partition plate flat. A heat-conducting silica gel is filled inside each unit chamber, and the filling height of the heat-conducting silica gel is higher than each unit shell and the inductance unit.
[0006] In a further technical solution, a hanging rod is formed on the side of each unit shell, and a positioning hook part is formed on the top of the hanging rod; a positioning slot is formed at the cavity opening of each unit chamber, and each positioning hook part is limited and engaged with the corresponding positioning slot during the assembly of the inner bracket and the inductor unit.
[0007] In a further technical solution, the inside of the unit shell is hollowed out to form a unit positioning cavity. The cross-sectional shape of the unit positioning cavity is semi-circular. The unit positioning cavity matches the outline size of the inductor unit, and each inductor unit is embedded and installed in the corresponding unit positioning cavity.
[0008] In a further technical solution, the inner surface of the unit positioning cavity is coated with an insulating layer, which includes a ceramic coating, a glass glaze coating, or a mica coating, and the thickness of the insulating layer is 0.3mm-0.8mm.
[0009] In a further technical solution, the upper opening of the die-cast aluminum shell is bent outwards to form an eave for assembly and positioning.
[0010] In a further technical solution, multiple heat dissipation fins are formed on the front and rear sides of the die-cast aluminum shell, and each heat dissipation fin is distributed at intervals on the front and rear sides of the die-cast aluminum shell and combined to form a heat dissipation surface structure.
[0011] In a further technical solution, the protrusion height of the heat dissipation fins is 4mm-7mm, and the protrusion height does not exceed the protrusion distance of the eaves. The thickness of the heat dissipation fins is 0.3mm-0.5mm. The interval between two adjacent heat dissipation fins is 0.5mm-0.8mm.
[0012] In a further technical solution, the left and right sides of the die-cast aluminum shell are formed with connecting parts for inductor mounting and fixing, and the bottom of the connecting parts is provided with internal threaded holes.
[0013] In a further technical solution, a filling gap is formed between the inner wall of each unit chamber and the outer wall of each unit shell for filling with thermally conductive silicone, wherein the size of the filling gap is 3mm-5mm.
[0014] The advantages of this invention compared to the prior art after adopting the above structure are:
[0015] 1. The inductor housing structure with an integrated inner bracket allows for pre-assembly of each inductor unit with the inner bracket, and then simultaneous embedding and installation of each inductor unit into its corresponding unit chamber. Through the positioning structure between the inner bracket and the die-cast aluminum housing, there is no need to perform positioning testing on each inductor unit, reducing the workflow and improving assembly efficiency of the combined inductors.
[0016] 2. The positioning connection between the inner bracket and the die-cast aluminum shell is sufficient to resist the impact of the thermally conductive silicone flow, eliminating the inductor unit misalignment from the structural source and ensuring product consistency.
[0017] 3. The insulating layer of the unit positioning cavity can strengthen the insulation isolation between the inductor unit and the inner bracket. Combined with thermally conductive silicone potting, it can achieve IP65 dustproof and waterproof protection, cope with harsh working conditions such as humidity and dust, and reduce the risk of insulation failure.
[0018] 4. The inductor unit is precisely positioned by the inner bracket, and the spatial position is consistent after potting. The dispersion of parameters such as inductance value and parasitic capacitance is reduced, and the deviation of electrical parameters can be controlled within ±2%, which meets the requirements of high-precision circuit design.
[0019] 5. The composite structure between the inner support and the die-cast aluminum shell, combined with the filling of thermally conductive silicone, ensures that the inductor unit remains secure and the solder joints remain unbroken under long-term high and low temperature and frequent vibration environments, thereby further extending the product's service life. Attached Figure Description
[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0021] Figure 1 This is a schematic diagram of the structure of this utility model.
[0022] Figure 2 This is an exploded view of the present invention.
[0023] Figure 3 This is a schematic diagram of the die-cast aluminum shell in this utility model. Detailed Implementation
[0024] The following are merely preferred embodiments of the present invention and do not limit the scope of protection of the present invention.
[0025] A highly integrated encapsulated combined inductor die-cast aluminum shell 1, comprising a die-cast aluminum shell 1, an inner bracket 2 and a plurality of inductor units 3. Among them, a plurality of partition plates 101 are formed at intervals along the length direction of the inner cavity of the die-cast aluminum shell 1 to form a plurality of unit chambers 10 for assembling each inductor unit 3. A recessed positioning slot hole 104 is provided at the bottom surface of each unit chamber 10, and a plurality of avoidance gaps 102 are recessed and formed at the top of the partition plate 101; the inner bracket 2 is made by die-casting aluminum material. The inner bracket 2 includes a plurality of unit shells 21, and a structural connection frame 22 is formed and connected between adjacent two unit shells 21. The structural connection frame 22 is arranged in an inverted U shape. A positioning protrusion is formed at the bottom surface of the unit shell 21. During assembly, each unit shell 21 of the inner bracket 2 is respectively embedded in the corresponding unit chamber 10, and its positioning protrusion is clamped in the corresponding positioning slot hole 104. At the same time, the tops of each structural connection frame 22 are respectively clamped in the corresponding avoidance gaps 102 to keep the top edge of the partition plate 101 flat. A heat-conducting silica gel is filled inside each unit chamber 10, and the filling height of the heat-conducting silica gel is higher than each unit shell 21 and the inductor unit 3.
[0026] An inductor shell structure provided with an integrally formed inner bracket 2 can pre-assemble each inductor unit 3 and the inner bracket 2, and then embed and install each inductor unit 3 into the corresponding unit chambers 10 at the same time. Through the positioning structure between the inner bracket 2 and the die-cast aluminum shell 1, there is no need to perform positioning detection on each inductor unit 3, reducing the work process and improving the assembly efficiency with a combined inductor.
[0027] The composite structure between the inner bracket 2 and the die-cast aluminum shell 1, combined with the filling of heat-conducting silica gel, can keep the inductor unit without looseness and the solder joints without fracture under the environmental conditions of long-term high and low temperatures and frequent vibrations, and further improve the service life of the product.
[0028] Specifically, a hanging rod 23 is respectively formed on the side part of each unit shell 21, and a positioning hanging part 231 bent outward is formed at the top of the hanging rod 23; positioning bayonets 103 are respectively formed at the cavity openings of each unit chamber 10. When the inner bracket 2 and the inductor unit 3 are assembled, each positioning hanging part 231 is respectively in limit fit with the corresponding positioning bayonet 103.
[0029] The positioning connection between the inner bracket 2 and the die-cast aluminum shell 1 is sufficient to resist the flow impact of the heat-conducting silica gel, preventing the inductor unit 3 from shifting from the structural root cause and ensuring the product consistency.
[0030] The inductor unit 3 is accurately limited by the inner bracket 2, and the spatial positions are consistent after encapsulation. The discreteness of parameters such as inductance value and parasitic capacitance is reduced, and the electrical parameter deviation can be controlled within ±2%, meeting the requirements of high-precision circuit design.
[0031] Specifically, the interior of the unit shell 21 is hollowed out to form a unit positioning cavity. The cross-sectional shape of the unit positioning cavity is semi-circular. The unit positioning cavity matches the outline size of the inductor unit 3. Each inductor unit 3 is embedded and installed in the corresponding unit positioning cavity.
[0032] Specifically, the inner surface of the unit positioning cavity is coated with an insulating layer, which includes a ceramic coating, a glass glaze coating, or a mica coating, and the thickness of the insulating layer is 0.3 mm.
[0033] The insulating layer of the unit positioning cavity can strengthen the insulation isolation between the inductor unit 3 and the inner bracket 2. Combined with thermally conductive silicone potting, it can achieve IP65 dustproof and waterproof protection, cope with harsh working conditions such as humidity and dust, and reduce the risk of insulation failure.
[0034] Specifically, the upper opening of the die-cast aluminum shell 1 is bent outwards to form an eave 12 for assembly and positioning.
[0035] Specifically, multiple heat dissipation fins 19 are formed on the front and rear sides of the die-cast aluminum shell 1, and each heat dissipation fin 19 is distributed at intervals on the front and rear sides of the die-cast aluminum shell 1, and they are combined to form a heat dissipation surface structure.
[0036] Specifically, the protrusion height of the heat dissipation fin 19 is 4, and its protrusion height does not exceed the protrusion distance of the eaves 12. The thickness of the heat dissipation fin 19 is 0.3. The interval between two adjacent heat dissipation fins 19 is 0.5.
[0037] Specifically, the left and right sides of the die-cast aluminum shell 1 are formed with connecting parts 11 for inductor installation and fixing, and the bottom of the connecting parts 11 is provided with internal thread holes.
[0038] Specifically, a filling gap is formed between the inner wall of each unit chamber 10 and the outer wall of each unit shell 21 for filling with thermally conductive silicone, wherein the size of the filling gap is 5mm.
[0039] The above description is only a preferred embodiment of this utility model. For those skilled in the art, there will be changes in the specific implementation method and application scope based on the idea of this utility model. The content of this specification should not be construed as a limitation of this utility model.
Claims
1. A highly integrated potted composite inductor die-cast aluminum shell (1), characterized in that: It includes a die-cast aluminum shell (1), an inner bracket (2), and multiple inductance units (3). Among them, multiple partition plates (101) are formed at intervals along the length direction of the inner cavity of the die-cast aluminum shell (1) to form multiple unit chambers (10) for assembling each inductance unit (3). A recessed positioning slot hole (104) is provided at the bottom surface of each unit chamber (10), and multiple avoidance gaps (102) are recessed and formed at the top of the partition plate (101). The inner bracket (2) is made by die-casting aluminum. The inner bracket (2) includes multiple unit shells (21). A structural connection frame (22) is formed and connected between adjacent two unit shells (21). The structural connection frame (22) is arranged in a "冂" shape. A positioning protrusion is formed at the bottom surface of the unit shell (21). During assembly, each unit shell (21) of the inner bracket (2) is respectively embedded in the corresponding unit chamber (10), and its positioning protrusion is clamped in the corresponding positioning slot hole (104). At the same time, the tops of each structural connection frame (22) are respectively clamped in the corresponding avoidance gaps (102) to keep the top edge of the partition plate (101) flat. Heat-conducting silica gel is filled inside each unit chamber (10), and the filling height of the heat-conducting silica gel is higher than each unit shell (21) and the inductance unit (3).
2. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 1, characterized in that: A hanging rod (23) is respectively formed at the side part of each unit shell (21), and a positioning hanging part (231) bent outward is formed at the top of the hanging rod (23). A positioning bayonet (103) is respectively formed at the opening of each unit chamber (10). When the inner bracket (2) and the inductance unit (3) are assembled, each positioning hanging part (231) is respectively in limit fit with the corresponding positioning bayonet (103).
3. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 2, characterized in that: The inside of the unit shell (21) is hollowed out to form a unit positioning cavity. The cross-sectional shape of the unit positioning cavity is semicircular, and the unit positioning cavity matches the contour size of the inductance unit (3). Each inductance unit (3) is respectively embedded and installed in the corresponding unit positioning cavity.
4. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 3, characterized in that: An insulating layer is coated on the inner surface of the unit positioning cavity. The insulating layer includes a ceramic coating, a glass glaze coating or a mica coating, and the thickness of the insulating layer is 0.3 mm - 0.8 mm.
5. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 1, characterized in that: The upper opening of the die-cast aluminum shell (1) is bent outward and forms an eaves part (12) for assembly positioning.
6. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 5, characterized in that: Multiple heat dissipation fins (19) are respectively formed on the front and rear side surfaces of the die-cast aluminum shell (1). Each heat dissipation fin (19) is respectively distributed at intervals on the front and rear side surfaces of the die-cast aluminum shell (1) and combined to form a heat dissipation surface structure.
7. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 6, characterized in that: The protruding height of the heat dissipation fin (19) is 4 mm - 7 mm, and its protruding height does not exceed the protruding distance of the eaves part (12). The thickness of the heat dissipation fin (19) is 0.3 mm - 0.5 mm; the interval between adjacent two heat dissipation fins (19) is 0.5 mm - 0.8 mm.
8. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 7, characterized in that: Connection parts (11) are formed on the left and right side surfaces of the die-cast aluminum shell (1) for installing and fixing the inductor. Threaded holes are provided at the bottom of the connection parts (11).
9. The highly integrated potted composite inductor die-cast aluminum shell (1) according to claim 1, characterized in that: A filling gap is formed between the inner wall of each unit chamber (10) and the outer wall of each unit shell (21) for filling the thermally conductive silicone, wherein the size of the filling gap is 3mm-5mm.