A potted inductor

Abstract

This invention provides a potted inductor, comprising a housing, a winding frame fixedly connected to the inner wall of the housing, a magnetic core disposed on the inner wall of the winding frame, multiple oxygen-free copper rods inserted into the inner wall of the magnetic core, multiple thermally conductive copper sheets mounted on the outer side of the winding frame, multiple thermally conductive ceramic pillars fixedly connected to the outer side of the magnetic core, a winding coil disposed on the outer side of the winding frame, and a cover plate disposed on the upper side of the housing. By using a heat dissipation structure composed of oxygen-free copper rods, thermally conductive ceramic pillars, and thermally conductive copper sheets, and filling the gap between the magnetic core and the winding frame with thermally conductive epoxy resin, the oxygen-free copper rods can quickly absorb the heat generated by the magnetic core, which is then transferred to the thermally conductive copper sheets via the thermally conductive ceramic pillars and dissipated to the external environment. The thermally conductive epoxy resin enhances the heat transfer between the magnetic core and the winding frame, improving the inductor's heat dissipation efficiency and ensuring the inductor's performance stability during long-term operation.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, specifically to a potted inductor. Background Technology

[0002] Encapsulated inductors are key components for energy conversion and signal filtering in electronic devices and are widely used in power modules, new energy vehicle electronic control systems and other fields. They achieve mechanical protection and electrical isolation by encapsulating the coil and magnetic core in an insulating potting material. At the same time, the heat generated during operation (mainly from magnetic core loss and coil Joule heat) is conducted to the outer shell and dissipated by relying on the thermal conductivity of the potting material.

[0003] However, the thermal design of existing potted inductors has shortcomings: on the one hand, although commonly used potting materials (such as epoxy and silicone) have excellent insulation properties, their thermal conductivity is generally low, making it difficult to meet the heat dissipation requirements of high-power scenarios. On the other hand, the heat of the magnetic core and coil needs to be indirectly conducted to the outer shell through the potting material, resulting in a large thermal resistance. Furthermore, the potting layer is prone to forming a heat conduction bottleneck due to air bubbles and uneven filling, leading to excessively high inductor operating temperature and affecting stability and service life. Utility Model Content

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a potted inductor to solve the problems mentioned in the background section. This invention features a novel structure, employing a heat dissipation structure composed of an oxygen-free copper rod, a thermally conductive ceramic pillar, and a thermally conductive copper sheet, along with thermally conductive epoxy resin filling the gap between the magnetic core and the winding frame. The oxygen-free copper rod can quickly absorb the heat generated by the magnetic core, which is then transferred to the thermally conductive copper sheet via the thermally conductive ceramic pillar and dissipated to the external environment. The thermally conductive epoxy resin enhances the heat transfer between the magnetic core and the winding frame, improving the inductor's heat dissipation efficiency and ensuring the inductor's performance stability during long-term operation.

[0005] To achieve the above objectives, this utility model is implemented through the following technical solution: a potted inductor includes a housing, a winding frame fixedly connected to the inner wall of the housing, a magnetic core disposed on the inner wall of the winding frame, multiple oxygen-free copper rods inserted into the inner wall of the magnetic core, multiple heat-conducting copper sheets mounted on the outer side of the winding frame, multiple heat-conducting ceramic pillars fixedly connected to the outer side of the magnetic core, a winding coil disposed on the outer side of the winding frame, a cover plate disposed on the upper side of the housing, connecting slot blocks fixedly connected to the lower side of the cover plate and the lower side of the inner wall of the housing, multiple positioning slots that cooperate with the oxygen-free copper rods are opened on opposite sides of the two connecting slot blocks, and limiting hole plates that cooperate with the oxygen-free copper rods are fixedly connected to both sides of the magnetic core.

[0006] Furthermore, the outer surface of the magnetic core is fitted with the inner wall of the winding frame with a gap, and the gap is filled with thermally conductive epoxy resin.

[0007] Furthermore, the outer surface of the oxygen-free copper rod is coated with a polyimide film.

[0008] Furthermore, the proximal ends of the plurality of thermally conductive ceramic pillars extend into the interior of the magnetic core and are fixedly connected to one side of the corresponding oxygen-free copper rod, while the distal ends of the plurality of thermally conductive ceramic pillars are in contact with one side of the corresponding thermally conductive copper sheet.

[0009] Furthermore, two pins are installed on the lower side of the housing, and the lower end of the winding coil extends to the lower side of the housing and is fixedly connected to the pins.

[0010] Furthermore, a potting pipe is installed on one side of the housing, and an exhaust hole is provided on the upper side of the cover plate.

[0011] Furthermore, the upper side of the cover plate is threaded with multiple fixing bolts, and the upper side of the housing is provided with multiple threaded holes corresponding to the fixing bolts. The lower ends of the multiple fixing bolts extend to the lower side of the cover plate and are threadedly engaged with the threaded holes.

[0012] Furthermore, a sealing ring is fixedly connected to the lower side of the cover plate, and a sealing groove that mates with the sealing ring is provided on the upper side of the housing.

[0013] The beneficial effects of this utility model are:

[0014] 1. This utility model uses a heat dissipation structure composed of an oxygen-free copper rod, a thermally conductive ceramic pillar, and a thermally conductive copper sheet, and fills the gap between the magnetic core and the winding frame with thermally conductive epoxy resin. The oxygen-free copper rod can quickly absorb the heat generated by the magnetic core, which is then transferred to the thermally conductive copper sheet via the thermally conductive ceramic pillar and then dissipated to the external environment. The thermally conductive epoxy resin enhances the heat transfer between the magnetic core and the winding frame, improves the heat dissipation efficiency of the inductor, and ensures the performance stability of the inductor during long-term operation.

[0015] 2. This utility model uses a sealing structure such as fixing bolts, sealing rings, and sealing grooves between the cover plate and the housing. The fixing bolts ensure a tight connection between the cover plate and the housing, while the sealing rings and sealing grooves enhance the sealing performance of the housing, preventing leakage of potting material and the entry of external impurities, extending the service life of the inductor, and ensuring its stable operation in complex environments. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall three-dimensional structure of a potted inductor according to the present invention;

[0017] Figure 2 This is a bottom view schematic diagram of the structure of a potted inductor according to the present invention;

[0018] Figure 3 This is a schematic diagram of the cover plate separation structure of a potted inductor according to the present invention;

[0019] Figure 4 This is a schematic diagram of the cross-sectional structure of the housing of a potted inductor according to the present invention;

[0020] Figure 5 This is an exploded view of the winding coil connection structure of a potted inductor according to the present invention.

[0021] Figure 6 This is a schematic diagram of the cross-sectional structure of the magnetic core of a potted inductor according to the present invention.

[0022] In the diagram: 1. Shell; 2. Winding frame; 3. Magnetic core; 4. Oxygen-free copper rod; 5. Thermally conductive copper sheet; 6. Thermally conductive ceramic column; 7. Winding coil; 8. Cover plate; 9. Connecting slot block; 10. Positioning slot; 11. Limiting hole plate; 12. Pin; 13. Encapsulation pipe; 14. Vent hole; 15. Fixing bolt; 16. Threaded hole; 17. Sealing ring; 18. Sealing groove. Detailed Implementation

[0023] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0024] Please refer to Figures 1 to 6This utility model provides a technical solution: a potted inductor, including a housing 1, a winding frame 2 fixedly connected to the inner wall of the housing 1, a magnetic core 3 disposed on the inner wall of the winding frame 2, multiple oxygen-free copper rods 4 inserted into the inner wall of the magnetic core 3, multiple heat-conducting copper sheets 5 mounted on the outer side of the winding frame 2, multiple heat-conducting ceramic pillars 6 fixedly connected to the outer side of the magnetic core 3, a winding coil 7 disposed on the outer side of the winding frame 2, a cover plate 8 disposed on the upper side of the housing 1, connecting slots 9 fixedly connected to the lower side of the cover plate 8 and the lower side of the inner wall of the housing 1, multiple positioning slots 10 that mate with the oxygen-free copper rods 4 are formed on opposite sides of the two connecting slots 9, and limiting holes 11 that mate with the oxygen-free copper rods 4 are fixedly connected to both sides of the magnetic core 3. The outer surface of the magnetic core 3 is in clearance fit with the inner wall of the winding frame 2, and the gap is filled with heat-conducting epoxy resin. The outer surface of the oxygen-free copper rods 4 is coated with a polyimide film. The proximal ends of multiple thermally conductive ceramic pillars 6 extend into the interior of the magnetic core 3 and are fixedly connected to one side of the corresponding oxygen-free copper rod 4, while the distal ends of the multiple thermally conductive ceramic pillars 6 are in contact with one side of the corresponding thermally conductive copper sheet 5. During assembly, the winding frame 2 is fixed to the inner wall of the housing 1, and the magnetic core 3 is placed inside the winding frame 2. The gap between the two is filled with thermally conductive epoxy resin to achieve a stable connection and enhance thermal conductivity. An oxygen-free copper rod 4 covered with a polyimide film is inserted into the inner wall of the magnetic core 3. The limiting plate 11 limits and prevents displacement. A thermally conductive copper sheet 5 is installed on the outside of the winding frame 2. A thermally conductive ceramic pillar 6 on the outside of the magnetic core 3 connects the oxygen-free copper rod 4 and the thermally conductive copper sheet 5. A winding coil 7 is installed outside the winding frame 2. After the cover plate 8 is closed, the positioning groove 10 of the connecting slot block 9 fixes the oxygen-free copper rod 4. In this process, the connection and cooperation of each component builds a stable structure for the normal operation of the inductor. The oxygen-free copper rod 4, the thermally conductive ceramic pillar 6 and the thermally conductive copper sheet 5 form an efficient heat dissipation path. The thermally conductive epoxy resin enhances the thermal conductivity between the magnetic core 3 and the winding frame 2, ensuring that the heat can be transferred and dissipated in time when the inductor is working.

[0025] In this embodiment, two pins 12 are mounted on the lower side of the housing 1, and the lower end of the winding coil 7 extends to the lower side of the housing 1 and is fixedly connected to the pins 12. A potting pipe 13 is mounted on one side of the housing 1, and an exhaust hole 14 is provided on the upper side of the cover plate 8. Multiple fixing bolts 15 are threadedly fitted on the upper side of the cover plate 8, and multiple threaded holes 16 are opened on the upper side of the housing 1 corresponding to the fixing bolts 15. The lower ends of the multiple fixing bolts 15 extend to the lower side of the cover plate 8 and are threadedly fitted to the threaded holes 16. A sealing ring 17 is fixedly connected to the lower side of the cover plate 8, and a sealing groove 18 that mates with the sealing ring 17 is opened on the upper side of the housing 1. After assembly, the pins 12 on the lower side of the housing 1 are connected to the winding coil 7 to realize circuit access. Material is poured in through the potting pipe 13, and the exhaust hole 14 vents to ensure full potting. The fixing bolts 15 and the threaded holes 16 cooperate to fix the cover plate 8. The sealing ring 17 and the sealing groove 18 enhance the sealing performance, prevent leakage and impurities from entering, ensure the sealing performance and structural stability of the inductor, and improve the overall stability.

[0026] When the device is in use, the winding coil 7 is connected to the circuit via pin 12. When energized, it generates electromagnetic induction. The magnetic core 3 enhances the magnetic field to achieve the basic function. The heat generated is absorbed by the oxygen-free copper rod 4 inside the magnetic core 3, and then transferred to the thermally conductive copper sheet 5 via the thermally conductive ceramic pillar 6. It is then dissipated through the potting material, the housing 1, and the cover plate 8. The thermally conductive epoxy resin in the gap between the magnetic core 3 and the winding frame 2 also assists in heat dissipation. The fixing and sealing structure of the cover plate 8 ensures that the housing 1 is sealed. The potting-related components ensure sufficient potting, and the various connection structures ensure the stability of the components, so that the inductor can work stably and efficiently.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. It is obvious to those skilled in the art that this utility model is not limited to the details of the above exemplary embodiments, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model.

[0028] 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 potted inductor comprising a housing (1), characterized in that: The inner wall of the housing (1) is fixedly connected to a winding frame (2), the inner wall of the winding frame (2) is provided with a magnetic core (3), the inner wall of the magnetic core (3) is inserted with multiple oxygen-free copper rods (4), the outer side of the winding frame (2) is provided with multiple heat-conducting copper sheets (5), the outer side of the magnetic core (3) is fixedly connected with multiple heat-conducting ceramic pillars (6), the outer side of the winding frame (2) is provided with a winding coil (7), the upper side of the housing (1) is provided with a cover plate (8), the lower side of the cover plate (8) and the lower side of the inner wall of the housing (1) are both fixedly connected with connecting slot blocks (9), the opposite side of the two connecting slot blocks (9) is provided with multiple positioning slots (10) that cooperate with oxygen-free copper rods (4), and the two sides of the magnetic core (3) are both fixedly connected with limiting hole plates (11) that cooperate with oxygen-free copper rods (4).

2. The potted inductor of claim 1, wherein: The outer surface of the magnetic core (3) is fitted with the inner wall of the winding frame (2) with a gap, and the gap is filled with thermally conductive epoxy resin.

3. The potted inductor according to claim 1, characterized in that: The outer surface of the oxygen-free copper rod (4) is covered with a polyimide film.

4. The potted inductor of claim 1, wherein: One of the adjacent ends of the plurality of thermally conductive ceramic pillars (6) extends into the interior of the magnetic core (3) and is fixedly connected to one side of the corresponding oxygen-free copper rod (4), and the other end of the plurality of thermally conductive ceramic pillars (6) contacts one side of the corresponding thermally conductive copper sheet (5).

5. The potted inductor of claim 1, wherein: Two pins (12) are mounted on the lower side of the housing (1), and the lower end of the winding coil (7) extends to the lower side of the housing (1) and is fixedly connected to the pins (12).

6. The potted inductor of claim 1, wherein: A filling pipe (13) is installed on one side of the housing (1), and an exhaust hole (14) is provided on the upper side of the cover plate (8).

7. The potted inductor of claim 1, wherein: The upper side of the cover plate (8) is threaded with multiple fixing bolts (15), and the upper side of the housing (1) is provided with multiple threaded holes (16) corresponding to the fixing bolts (15). The lower ends of the multiple fixing bolts (15) extend to the lower side of the cover plate (8) and are threadedly engaged with the threaded holes (16).

8. The potted inductor of claim 1, wherein: A sealing ring (17) is fixedly connected to the lower side of the cover plate (8), and a sealing groove (18) that matches the sealing ring (17) is provided on the upper side of the housing (1).

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