A power inductor

Abstract

The utility model discloses a kind of power inductors, by the cooperation base assembly of a group of magnetic ring splicing into annular cylinder with prefabricated flat coil, wherein flat coil is annular winding with turn gap zero under prefabricated state, flat coil is reversed and folded to show fin ring under assembly state, two free ends of flat coil are extended in parallel in two states, magnetic ring is inserted in fin ring and is bonded to receive port, under the state that flat coil wraps closed loop magnetic ring, two free ends are penetrated and fixed to base. The inductor effectively solves the production problem of using flat wire to wind circular power inductor by optimizing the variable shape of flat coil prefabrication and assembly and splitting and splicing magnetic ring for embedded assembly, effectively improves the current-carrying capacity of inductor device, improves its DC-DC Converter Buck circuit conversion efficiency under the condition of reducing copper loss and iron loss.

Description

Technical Field

[0001] This utility model relates to an inductor, and more particularly to a power inductor, belonging to the field of basic electronic components technology. Background Technology

[0002] Inductors are one of the most commonly used components in electronic devices, widely used in various circuits to perform functions such as filtering, energy storage, matching, and resonance. With the increasing miniaturization and portability of electronic products, and the high-density assembly of components, inductor components have developed rapidly. Furthermore, considering electromagnetic compatibility, the ability of electronic products to resist electromagnetic interference has become a basic design requirement, thus increasing the demand for and application of inductors.

[0003] Currently, the common structure of inductors in the industry is a fully enclosed device with a magnetic core wrapped around an iron core. However, as the circuit is used for a long time, the inductor gradually accumulates heat and rises in temperature. Furthermore, due to the miniaturization of the cell size, the current withstand capability of the inductor is weakened, which affects the performance of the inductor. Summary of the Invention

[0004] The purpose of this invention is to propose a power inductor that aims to improve the conversion efficiency of inductors in Buck / Boost circuits.

[0005] The technical solution of this utility model to achieve the above-mentioned objective is: a power inductor, which is assembled from a pre-formed flat coil and a set of magnetic rings that can be spliced ​​into a ring-shaped column with a base. The flat coil is a ring-shaped winding with zero turn gap in the pre-formed state, and a finned ring folded in the opposite direction in the assembled state. In both states, the two free ends of the flat coil extend in parallel in the same direction. The magnetic ring is inserted into the finned ring and glued to the receiving port. In the state where the flat coil is wrapped around the closed magnetic ring, the two free ends penetrate and are fixed to the base.

[0006] Furthermore, in the prefabricated state, the flat coil is a ring-shaped coil formed by continuously winding enameled copper flat wire around a forming column, with the width of the enameled copper flat wire overlapping and contacting the surface, and the cross-sectional profile of the forming column being compatible with the axial section of the magnetic ring.

[0007] Furthermore, in the assembled state, the fin ring shape formed by the flat coil is the same as the shape of the closed-loop magnetic ring.

[0008] Furthermore, the closed-loop magnetic ring is a cylindrical ring, and the magnetic ring is a C-shaped body that is cut in half.

[0009] Furthermore, the closed-loop magnetic ring is a rounded square ring cylinder, and the magnetic ring is a U-shaped body cut in half or a C-shaped body cut in four corners.

[0010] Furthermore, the magnetic ring is a cured block formed by cold pressing powder material using a custom mold and treated with epoxy spraying insulation.

[0011] Furthermore, the base is provided with at least one set of through holes that penetrate its own thickness direction. The position between the two through holes in each set corresponds to the relative position of the two free ends in the fin ring state, and the hole shape of each through hole is suitable for the free end of the flat copper wire to be connected in series and seamlessly fitted and clamped.

[0012] Compared with the prior art, the advantages of the inductor of this utility model are reflected in the following aspects: by optimizing the variable shape of the prefabrication and assembly of the flat coil and cutting and splicing the magnetic ring for embedded assembly, the production problem of using flat wire to wind circular power inductors is effectively solved. At the same time, the current withstand capability of the inductor is effectively improved, and its conversion efficiency in DC-DC Converter Buck circuit is improved while reducing copper loss and iron loss. Attached Figure Description

[0013] Figure 1 This is a three-dimensional structural diagram of the finished power inductor of this utility model.

[0014] Figure 2 This is a schematic diagram illustrating the structural evolution of the production and assembly of the power inductor of this utility model. Detailed Implementation

[0015] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.

[0016] This invention proposes a power inductor, aiming to improve the performance of inductor devices and the conversion efficiency of the transformer circuits in which they are applied. For example... Figures 1 to 2 As shown, the basic structure of this inductor consists of a pre-formed flat coil 1 and a set of magnetic rings that can be assembled into a ring-shaped cylinder, combined with a base 3. In its pre-formed state, the flat coil 1 is a ring-shaped winding 1a with zero turn gap. In its assembled state, the flat coil is folded in the opposite direction to form a finned ring 1b. In both states, the two free ends of the flat coil extend parallel to each other in the same direction. The magnetic rings are inserted into the finned rings and adhered to the receiving port. When the flat coil is wrapped around the closed-loop magnetic ring, the two free ends penetrate and are fixed to the base. Due to the auxiliary shaping effect of the base on the finned ring, the assembly structure of the flat coil and magnetic rings is more stable.

[0017] Depend on Figure 1As shown, this new type of power inductor uses a structure where the battery cell is wrapped around a magnetic core, which significantly increases the battery cell area. This improves the inductor's current handling capability and heat dissipation during operation. Furthermore, the assembly process is greatly simplified, avoiding additional copper and iron losses caused by high-temperature, high-pressure manufacturing processes.

[0018] Looking at the details further, in the prefabricated state, the flat coil is a ring-shaped coil 1a formed by continuously winding enameled copper flat wire around a forming column. Figure 1 (As shown in the upper left corner), and during continuous winding, the width of the enameled copper flat wire overlaps and contacts the surface. The cross-sectional profile of the forming column is compatible with the axial section of the magnetic ring, meaning the magnetic ring can freely pass through the winding hole during the pre-fabrication of the flat coil. When the flat coil is folded in the reverse to form a finned ring 1b, the winding hole deforms into an annular channel. Of course, the finned ring after the flat coil is folded in the reverse has a flexible adjustable local spacing, and the shape of the formed finned ring needs to be the same as the shape of the closed-loop magnetic ring.

[0019] like Figure 1 In the preferred embodiment shown, the closed-loop magnetic ring is a cylindrical ring, and the magnetic ring includes a first C-shaped body 21 and a second C-shaped body 22 cut in half. The magnetic ring is a cured block formed by cold pressing powder material using a custom mold and treated with epoxy spraying insulation. The powder material is one or more combinations of FeSi / FeSiAl / FeSiCr / amorphous / nanocrystalline. The first and second C-shaped bodies penetrate the aforementioned "annular channel" of the finned ring from two directions and close into a ring shape. As shown in the figure, the flat coil opens and closes uniformly during the formation of the finned ring, meaning the spacing between each fin is basically consistent. The base 3 is provided with at least one set (preferably one set) of through holes 31 penetrating its own thickness direction. The position between any two through holes in any set corresponds to the relative position of the two free ends in the finned ring state, and the hole shape of each through hole is suitable for connecting the free end of a flat copper wire in series and seamlessly engaging and locking it in place.

[0020] In addition to the preferred embodiment, the magnetic ring of the closed loop described above can also be a rounded square ring cylinder, and the magnetic ring can be a U-shaped body cut in half or a C-shaped body cut at four corners. It should be noted that the cross-sectional shape of the magnetic ring at the corners does not exceed the cross-sectional outline described above.

[0021] like Figure 2As shown in the schematic diagram of the complete manufacturing process of the preferred embodiment (ring-shaped) of the power inductor: First, enameled copper flat wire is wound into a ring shape, with its two free ends extending in the same direction and parallel. Then, the free ends are folded in the opposite direction, causing the ring shape to unfold into a finned ring. Next, a first C-shaped body is inserted through one end of the ring channel to obtain a preliminary assembly A, in which one side of the finned ring is supported and stable, while the other side of the finned ring is relatively loose. Then, a second C-shaped body is inserted through the other end of the ring channel to obtain a fully assembled assembly B, in which all the finned rings are supported and stable. Finally, the free ends are inserted into the holes of the base to fix the finished product C.

[0022] As can be seen from the detailed description of the preferred embodiment of the power inductor of this utility model, compared with the prior art, its technical effects are as follows: by optimizing the variable shape of the prefabrication and assembly of the flat coil and the cutting and splicing of the magnetic ring for embedded assembly, the production problem of using flat wire to wind circular power inductors is effectively solved, while effectively improving the current withstand capability of the inductor device and improving its conversion efficiency in DC-DC Converter Buck circuit while reducing copper loss and iron loss.

[0023] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the principles of this application should be included within the protection scope of this application.

Claims

1. A power inductor characterized by: The inductor is assembled from a pre-formed flat coil and a set of magnetic rings that can be spliced ​​into a ring-shaped column, along with a base. The flat coil is a ring-shaped winding with zero turn gap in the pre-formed state, and a finned ring folded in the reverse direction in the assembled state. In both states, the two free ends of the flat coil extend in parallel in the same direction. The magnetic ring is inserted into the finned ring and glued to the receiving port. In the state where the flat coil is wrapped around the closed magnetic ring, the two free ends penetrate and are fixed to the base.

2. The power inductor of claim 1, wherein: In the prefabricated state, the flat coil is a ring-shaped coil formed by continuously winding enameled copper flat wire around a forming column. The width of the enameled copper flat wire is stacked and contacted on the surface, and the cross-sectional profile of the forming column is adapted to the axial section of the magnetic ring.

3. The power inductor of claim 1, wherein: In the assembled state, the fin ring shape formed by the flat coil is the same as the shape of the closed-loop magnetic ring.

4. The power inductor of claim 1, wherein: The closed-loop magnetic ring is a cylindrical ring, and the magnetic ring is a C-shaped body that is cut in half.

5. The power inductor of claim 1, wherein: The closed-loop magnetic ring is a rounded square ring cylinder, and the magnetic ring is a U-shaped body cut in half or a C-shaped body cut in four corners.

6. The power inductor of claim 1, 4 or 5, wherein: The magnetic ring is a cured block formed by cold pressing powder material based on a customized mold and treated with epoxy spraying insulation.

7. The power inductor of claim 1, wherein: The base is provided with at least one set of through holes that penetrate its own thickness direction. The position between two through holes in each set corresponds to the relative position of the two free ends in the fin ring state. The hole shape of each through hole is suitable for the free end of the flat copper wire to be connected in series and fit together and be clamped.

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