Low cost photovoltaic copper clad aluminum differential mode inductor

Abstract

This utility model belongs to the field of electronic component technology and discloses a low-cost photovoltaic copper-clad aluminum differential mode inductor. The differential mode inductor includes a magnetic core assembly, copper-clad aluminum wire, and copper-aluminum transition terminals. The copper-clad aluminum wire is wound on the magnetic core assembly, and the copper-aluminum transition terminals are welded to both ends of the copper-clad aluminum wire. The magnetic circuit length of the magnetic core assembly is 12.5±0.2cm, and the magnetic core coefficient is 138nH to 163nH. The copper-aluminum mass ratio of the copper-clad aluminum wire is 30:70, and the density of the copper-clad aluminum wire is 3.63×10⁻⁶g / mm³. This utility model's low-cost photovoltaic copper-clad aluminum differential mode inductor uses 30:70 copper-aluminum wire, increasing the cross-sectional area by 20% to compensate for thermal conductivity, reducing costs by more than 50%. Furthermore, through core size optimization and a 45° tilted winding design, weight is reduced, window space utilization is improved, and high efficiency and lightweight design are achieved.

Description

Technical Field

[0001] This utility model belongs to the field of electronic component technology, and more specifically, it relates to a low-cost photovoltaic copper-clad aluminum differential mode inductor. Background Technology

[0002] As power electronic devices such as photovoltaic inverters develop towards higher frequencies and lighter weights, differential-mode inductors, as core components for suppressing electromagnetic interference, face severe challenges in cost control and heat dissipation performance. Traditional solutions primarily use pure copper wire to wind the inductor coil, which, while offering excellent conductivity, suffers from the following inherent drawbacks: I. High material costs: A single copper inductor in a pure copper solution typically weighs 163.6g. Due to the continuous rise in global copper prices, raw material costs account for more than 60% of the total cost, which seriously restricts the product's competitiveness.

[0003] II. Lightweighting Bottleneck: Density of pure copper (8.96×10⁻⁻⁶) 6 The weight of the inductor (g / mm³) is too large, making it difficult to meet the weight reduction requirements of portable devices and high power density systems.

[0004] Third, low space utilization: In order to maintain inductance consistency, traditional magnetic core design requires more winding turns, resulting in insufficient window fill rate, which restricts the development of miniaturization.

[0005] Therefore, this invention provides a low-cost copper-clad aluminum differential mode inductor for photovoltaics. Utility Model Content

[0006] In view of the above-mentioned problems of existing technology, the purpose of this utility model is to provide a low-cost photovoltaic copper-clad aluminum differential mode inductor. This low-cost photovoltaic copper-clad aluminum differential mode inductor uses 30:70 copper-aluminum wire, increases the cross-sectional area by 20% to compensate for thermal conductivity, and reduces the cost by more than 50%. Furthermore, through core size optimization and 45° tilted winding design, the weight is reduced and the window space utilization is improved, achieving high efficiency and lightweight design.

[0007] The objective of this utility model can be achieved through the following technical solutions: A low-cost photovoltaic copper-clad aluminum differential mode inductor includes a magnetic core assembly, a copper-clad aluminum conductor, and a copper-aluminum transition terminal. The copper-clad aluminum conductor is wound around the magnetic core assembly, and the copper-aluminum transition terminal is welded to both ends of the copper-clad aluminum conductor.

[0008] As a further preferred technical solution of this utility model, the magnetic circuit length of the magnetic core assembly is 12.5±0.2cm, the magnetic core coefficient of the magnetic core assembly is 138nH to 163nH, the copper-aluminum mass ratio of the copper-clad aluminum wire is 30:70, and the density of the copper-clad aluminum wire is 3.63×10⁻ 6g / mm³.

[0009] The copper-clad aluminum wire is wound on the magnetic core assembly with 69 to 75 turns, and the diameter of the copper-clad aluminum wire is 15% to 20% larger than that of pure copper wire of the same specification.

[0010] As a further preferred technical solution of this utility model, the magnetic core assembly is a toroidal magnetic core with an outer diameter of 57.15±0.1mm, an inner diameter of 26.39±0.1mm, a height of 18±0.1mm, and an AE value of 2.7±0.1cm².

[0011] As a further preferred technical solution of this utility model, the annular magnetic core is provided with a spacer groove, the spacer groove is provided with a partition plate, and the copper-clad aluminum wire is wound on the magnetic core assembly at a 45° angle.

[0012] As a further preferred technical solution of this utility model, the copper-aluminum transition terminal includes a copper welding head, a gradient alloy transition layer, and an insulating positioning sleeve. The length of the copper welding head is not less than three times the diameter of the copper-clad aluminum wire; The copper content of the gradient alloy transition layer gradually changes from 100% to 30%. The insulating positioning sleeve covers the outlet of the copper-clad aluminum conductor.

[0013] As a further preferred technical solution of this utility model, the copper layer thickness of the copper-clad aluminum conductor is 10% to 15% of the diameter of the copper-clad aluminum conductor; The ratio of the window cross-sectional area of ​​the magnetic core assembly to the cross-sectional area of ​​the copper-clad aluminum conductor is 4.8:1 to 5.2:1.

[0014] As a further preferred technical solution of this utility model, the surface of the magnetic core assembly is coated with a nanocrystalline insulating layer, the thickness of which is 0.05-0.1 mm.

[0015] As a further preferred technical solution of this utility model, the magnetic core assembly is made of magnetic powder core material, and the magnetic permeability of the magnetic core assembly is in the range of 30000~50000H / m.

[0016] As a further preferred technical solution of this utility model, the spacer groove and the partition plate are filled with silicone thermally conductive adhesive.

[0017] As a further preferred technical solution of this utility model, the gap between the winding turns of the copper-clad aluminum wire wound on the magnetic core assembly is 0.8-1.2 times the diameter of the wire, and the gap between the winding turns is provided with high-temperature resistant insulating paper.

[0018] As described above, the low-cost photovoltaic copper-clad aluminum differential mode inductor provided by this utility model has the following beneficial effects: 1. This utility model utilizes the aforementioned low-cost photovoltaic copper-clad aluminum differential mode inductor. Compared with existing technologies, due to its structure, it employs copper-clad aluminum wire with a copper-to-aluminum mass ratio of 30:70, combined with gradient alloy transition terminals. While ensuring conductivity, it replaces the traditional 2.0mm pure copper wire with a 2.3mm diameter copper-clad aluminum wire, increasing the wire cross-sectional area by approximately 20% to compensate for thermal conductivity differences. However, the cost is only "30% copper price + 70% aluminum price". For the same inductance (776uH), the copper wire solution weighs 163.6g, while the copper-clad aluminum solution weighs only 98.5g. Combined with the metal price difference, the cost is reduced by more than 50%.

[0019] 2. This utility model utilizes the aforementioned low-cost photovoltaic copper-clad aluminum differential mode inductor. Compared with existing technologies, due to this structure, the copper-clad aluminum conductor density (3.63 × 10⁻⁻⁴) is significantly reduced. 6 The g / mm³ is significantly lower than that of pure copper (8.96×10⁻). 6 With an increase in core size (outer diameter 57.15mm / inner diameter 26.39mm / height 18mm), the weight of the inductor of the same specification is reduced by 39.7%; in addition, the height of the toroidal core is increased from the traditional 15.24mm to 18mm, and with the 45° tilted winding, the window space utilization is improved by 15%; furthermore, the core coefficient is optimized to 163nH, and the same inductance is achieved with fewer turns, reducing the space occupied by the winding.

[0020] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a front view of a low-cost photovoltaic copper-clad aluminum differential mode inductor according to this utility model application. Figure 2A side view of a low-cost photovoltaic copper-clad aluminum differential mode inductor according to this utility model application; Figure 3 This is a top view of a low-cost photovoltaic copper-clad aluminum differential mode inductor according to this utility model application.

[0023] Summary of figure labels and their descriptions: 100. Differential mode inductor; 200. Magnetic core assembly; 210. Spacer slot; 220. Partition plate; 300. Copper-clad aluminum conductor; 400. Copper-aluminum transition terminal; 410. Copper weld head; 420. Gradient alloy transition layer; 430. Insulating positioning sleeve. Detailed Implementation

[0024] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0025] It should be noted that the structures, proportions, and sizes depicted in the accompanying drawings are merely for illustrative purposes and to aid those skilled in the art. They are not intended to limit the scope of this invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, provided they do not affect the effectiveness or purpose of this invention, should still fall within the scope of the technical content disclosed herein. Furthermore, the terms "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of this invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of this invention. Specific structures can be described with reference to the accompanying drawings of the patent application.

[0026] This invention provides a low-cost copper-clad aluminum differential mode inductor for photovoltaics. Please refer to [link / reference]. Figures 1 to 3 As shown, the differential mode inductor 100 includes a magnetic core assembly 200, a copper-clad aluminum wire 300, and a copper-aluminum transition terminal 400. The copper-clad aluminum wire 300 is wound around the magnetic core assembly 200, and the copper-aluminum transition terminal 400 is welded to both ends of the copper-clad aluminum wire 300. The magnetic core assembly 200 has a magnetic circuit length of 12.5 ± 0.2 cm and a core coefficient of 138 nH to 163 nH. The copper-clad aluminum conductor 300 has a copper-to-aluminum mass ratio of 30:70, and its density is 3.63 × 10⁻⁻⁻⁶. 6 g / mm³.

[0027] It should be noted that this application uses a copper-clad aluminum conductor 300 with a copper-aluminum mass ratio of 30:70, combined with a copper-aluminum transition terminal 400 structure. By replacing pure copper with a high proportion of aluminum material (70%), the raw material cost is reduced by more than 50%; furthermore, the density of the copper-clad aluminum conductor 300 is 3.63×10⁻⁻⁶. 6 The thermal conductivity (g / mm³) is significantly lower than that of pure copper, reducing the conductor weight by approximately 40% (from 163.5g to 98.5g), making it suitable for weight-sensitive power electronic devices. Furthermore, by limiting the core magnetic circuit length (12.5±0.2cm) and core coefficient (138–163nH), the cross-sectional area requirement of the copper-clad aluminum conductor 300 is matched, ensuring that the equivalent loss can still be maintained even when the thermal conductivity is lower than that of pure copper, thus avoiding excessive temperature rise.

[0028] The copper-clad aluminum wire 300 is wound on the magnetic core assembly 200 with 69 to 75 turns. The diameter of the copper-clad aluminum wire 300 is 15% to 20% larger than that of pure copper wire of the same specification. The increased cross-sectional area compensates for the insufficient thermal conductivity of aluminum and keeps the total heat loss constant. The increased wire diameter and optimized number of turns are designed in synergy to achieve inductance consistency and volume control under the limitation of magnetic core window area.

[0029] The magnetic core assembly 200 is a toroidal magnetic core with an outer diameter of 57.15±0.1mm, an inner diameter of 26.39±0.1mm, and a height of 18±0.1mm. The size limitation of the toroidal magnetic core provides optimal space layout for the enlarged copper-clad aluminum conductor 300, avoiding volume expansion of the magnetic core due to the increase in cross-sectional area. The AE value of the toroidal magnetic core is 2.7±0.1cm², supporting higher magnetic flux and offsetting the effect of increased conductor resistance.

[0030] The annular magnetic core is provided with a spacer groove 210, and a partition plate 220 is provided on the spacer groove 210. The copper-clad aluminum wire 300 is wound on the magnetic core assembly 200 at a 45° angle. The 45° angled winding design releases the space at the top of the magnetic core, solves the wiring congestion problem after the wire diameter is increased, improves heat dissipation efficiency, and the angled winding reduces stress concentration between the wire and the copper-aluminum transition terminal 400, reducing the risk of solder joint breakage.

[0031] The copper-aluminum transition terminal 400 includes a copper welding head 410, a gradient alloy transition layer 420, and an insulating positioning sleeve 430. The length of the copper welding head 410 is not less than three times the diameter of the copper-clad aluminum wire 300; The copper content of the gradient alloy transition layer 420 gradually changes from 100% to 30%, eliminating the metallurgical incompatibility of direct copper-aluminum welding, inhibiting the formation of brittle interfacial compounds, and improving the mechanical strength of the terminals. The insulating positioning sleeve 430 covers the outlet of the copper-clad aluminum wire 300. The insulating positioning sleeve 430 covers the outlet of the wire to prevent the copper-aluminum transition terminal 400 from short-circuiting with the magnetic core, and is suitable for high-density circuit environments.

[0032] The copper layer thickness of the copper-clad aluminum conductor 300 is 10% to 15% of the diameter of the copper-clad aluminum conductor 300, to ensure surface current conduction efficiency (skin effect optimization) while controlling the amount of high-cost copper material used. The ratio of the window cross-sectional area of ​​the magnetic core assembly 200 to the cross-sectional area of ​​the copper-clad aluminum wire 300 is 4.8:1 to 5.2:1, which ensures the compactness of the winding and avoids the loss of control over the core size due to the increase in wire diameter.

[0033] The surface of the magnetic core assembly 200 is coated with a nanocrystalline insulating layer, the thickness of which is 0.05 to 0.1 mm. The nanocrystalline insulating layer covers the surface of the magnetic core, reducing eddy current losses, and is especially suitable for high-frequency switching scenarios in photovoltaic inverters. Furthermore, the nanocrystalline insulating layer provides a uniform dielectric barrier to prevent inter-turn breakdown.

[0034] The magnetic core assembly 200 is made of magnetic powder core material, and the magnetic permeability of the magnetic core assembly 200 ranges from 30,000 to 50,000 H / m. The magnetic powder core material allows for a reduction in the number of turns, reduces the resistance loss of the copper-clad aluminum wire 300, improves energy efficiency, and the iron-based material and the copper-clad aluminum wire 300 form a dual cost reduction combination.

[0035] The spacer groove 210 and the partition plate 220 are filled with silicone thermally conductive adhesive. The silicone thermally conductive adhesive establishes a rapid heat transfer channel from the magnetic core to the terminal, solving the problem of local overheating of copper-clad aluminum.

[0036] The 300 turns of copper-clad aluminum wire wound on the magnetic core assembly 200 have a winding gap of 0.8-1.2 times the wire diameter, and the winding gap is provided with high-temperature resistant insulating paper; the winding gap (0.8-1.2 times the wire diameter) combined with the high-temperature resistant insulating paper enhances the air convection heat dissipation capacity and avoids the accumulation of local hot spots caused by the increase in wire diameter.

[0037] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A low cost photovoltaic copper clad aluminum differential mode inductor, characterized by, The differential mode inductor includes a magnetic core assembly, a copper-clad aluminum conductor, and a copper-aluminum transition terminal. The copper-clad aluminum conductor is wound around the magnetic core assembly, and the copper-aluminum transition terminal is welded to both ends of the copper-clad aluminum conductor.

2. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 1, wherein, The magnetic circuit length of the magnetic core assembly is 12.5±0.2cm, the magnetic core coefficient of the magnetic core assembly is 138nH to 163nH, the copper-aluminum mass ratio of the copper-clad aluminum wire is 30:70, and the density of the copper-clad aluminum wire is 3.63×10 6 g / mm³; The copper-clad aluminum wire is wound on the magnetic core assembly with 69 to 75 turns, and the diameter of the copper-clad aluminum wire is 15% to 20% larger than that of pure copper wire of the same specification.

3. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 2, wherein, The magnetic core assembly is a toroidal magnetic core with an outer diameter of 57.15±0.1mm, an inner diameter of 26.39±0.1mm, a height of 18±0.1mm, and an AE value of 2.7±0.1cm².

4. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 3, wherein, The annular magnetic core is provided with a spacer groove, and a partition is provided on the spacer groove. The copper-clad aluminum wire is wound on the magnetic core assembly at a 45° angle.

5. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 1, wherein, The copper-aluminum transition terminal includes a copper welding head, a gradient alloy transition layer, and an insulating positioning sleeve; The length of the copper welding head is not less than three times the diameter of the copper-clad aluminum wire; The copper content of the gradient alloy transition layer gradually changes from 100% to 30%. The insulating positioning sleeve covers the outlet of the copper-clad aluminum conductor.

6. The low cost photovoltaic copper clad aluminum differential mode inductor of any of claims 1-4, wherein, The copper layer thickness of the copper-clad aluminum conductor is 10% to 15% of the diameter of the copper-clad aluminum conductor. The ratio of the window cross-sectional area of ​​the magnetic core assembly to the cross-sectional area of ​​the copper-clad aluminum conductor is 4.8:1 to 5.2:

1.

7. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 1, wherein, The surface of the magnetic core assembly is coated with a nanocrystalline insulating layer, the thickness of which is 0.05–0.1 mm.

8. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 1, wherein, The magnetic core assembly is made of magnetic powder core material, and the magnetic permeability of the magnetic core assembly is in the range of 30,000 to 50,000 H / m.

9. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 4, wherein, The spacer groove and the partition plate are filled with silicone thermally conductive adhesive.

10. The low cost photovoltaic copper clad aluminum differential mode inductor of claim 1, wherein, The gap between the copper-clad aluminum wire turns wound on the magnetic core assembly is 0.8-1.2 times the wire diameter, and the gap between the wire turns is provided with high-temperature resistant insulating paper.

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