An inductor with adjustable leakage inductance magnetic integration
By integrating an inductor into an LLC circuit and using a film-coated wire winding and a semi-circular magnetic ring to control leakage inductance, the problems of complex circuits, high cost, and difficulty in controlling leakage inductance in existing technologies are solved. This achieves miniaturization and cost reduction of the inductor, and improves the flexibility and accuracy of leakage inductance control.
Patent Information
- Application Number
- CN202521969274.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-12
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-09-12
AI Technical Summary
In existing LLC circuits, the transformer and resonant inductor are independent components, resulting in large size, complex circuitry, high processing costs, difficulty in controlling leakage inductance, and a high leakage inductance failure rate.
An adjustable leakage inductance magnetic integrated inductor is adopted. The leakage inductance is controlled by winding a film-coated wire around the frame and using a semi-circular magnetic ring. Combined with thermally conductive adhesive insulation and heat dissipation design, the independent resonant inductor is eliminated, and the leakage inductance is controlled by the coupling between the primary and secondary windings.
It achieves miniaturization of inductors, reduces costs, improves the flexibility and accuracy of leakage inductance control, reduces temperature rise and leakage inductance failure rate, and is applicable to various leakage inductance modes.
Smart Images
Figure CN224682915U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of magnetic components technology, specifically to an adjustable leakage inductance integrated inductor. Background Technology
[0002] Magnetic components typically involve fabricating transformers and resonant inductors as two separate units, a practice widely used in traditional LLC circuits. However, with rising material costs, the advantages of using two separate components are becoming less pronounced, resulting in larger size, more complex circuits, and relatively higher manufacturing costs.
[0003] Therefore, this utility model proposes an adjustable leakage magnetic integrated inductor. Utility Model Content
[0004] The purpose of this invention is to provide an adjustable leakage inductance integrated inductor to solve the problems mentioned in the background art.
[0005] To achieve the above objectives, the present invention provides the following technical solution: an adjustable leakage inductance magnetic integrated inductor, comprising a frame, a film-wrapped wire winding wound around the outside of the frame, the film-wrapped wire winding being multi-stranded, each film-wrapped wire winding being multi-stage, and a semi-circular magnetic ring installed between the primary and secondary stages of the film-wrapped wire winding.
[0006] Preferably, each strand of the membrane-coated wire is wound on two symmetrical winding slots, which are formed on the skeleton. The winding slots can separate the primary and secondary windings of the membrane-coated wire. The winding slots on two adjacent strands of the membrane-coated wire are separated and hollow, and the hollow areas are filled with thermally conductive adhesive.
[0007] Preferably, the semicircular magnetic ring is used to control the size of the leakage inductance. The leakage inductance is controlled by changing the size of the semicircular magnetic ring. The leakage inductance is used as a resonant inductor in an LLC circuit.
[0008] Preferably, multiple strands of the membrane-wrapped wire are wound on the winding groove, and the winding groove extends out at both ends of each group of membrane-wrapped wire windings. The portion of the membrane-wrapped wire winding extending out of the winding groove serves as a pin, and the pin is fixed to the skeleton.
[0009] Preferably, magnetic cores are installed at both ends of the skeleton. The magnetic cores are semi-enclosed PQ magnetic cores and are in the shape of a ring. The film-wrapped wire is wound around the inner circumference of the magnetic core.
[0010] Preferably, the size of the semi-circular magnetic ring can be freely adjusted.
[0011] Compared with the prior art, the beneficial effects of this utility model are:
[0012] 1. This utility model involves winding a membrane-coated wire onto a frame, then soldering one end of the membrane-coated wire winding from the winding slot to form a pin, and welding the pin to the frame. The magnetic core is made of ferric oxide, manganese tetroxide, zinc oxide, etc. The magnetic core is divided into three parts: an upper magnetic core, a lower magnetic core, and a middle sheet magnetic ring. The frame is the iron core column of the transformer. The semi-circular magnetic ring is used to control the magnetic flux of the primary and secondary windings, thereby controlling the leakage inductance.
[0013] 2. This utility model uses a membrane-wrapped coil, which provides insulation between the wires, thus avoiding short circuits between windings. The winding slots on adjacent membrane-wrapped wire windings are separated and hollow, and the hollow area is filled with thermally conductive adhesive. The thermally conductive adhesive in the hollow area forms insulation and heat conduction, thus creating insulation between adjacent membrane-wrapped wire windings and conducting and dissipating the heat generated by the membrane-wrapped wire windings during operation, thereby reducing the temperature rise of this transformer.
[0014] 3. In traditional LLC circuits, the transformer and resonant inductor are separate components, which have relatively high processing costs. However, by using the transformer in this invention, the independent resonant inductor in the traditional LLC circuit is eliminated through primary and secondary coupling by a customized frame. The leakage inductance of the transformer is used as the resonant inductor, which can save resources. However, the leakage inductance is controlled by the direct distance between the primary and secondary sides, which increases the manufacturing difficulty of the production line and the leakage inductance defect rate. The size of the leakage inductance can be used as the resonant inductance of the LLC circuit. Through the special design of the frame, plus the semi-circular magnetic ring, the size of the leakage inductance can be flexibly controlled, which perfectly solves this problem and technical difficulty, and is more conducive to the use of various leakage inductance size modes in LLC circuits.
[0015] 4. From a cost perspective, this utility model adopts this transformer structure, which integrates the inductance of the resonant inductor required in the LLC circuit, thus reducing material costs.
[0016] 5. In terms of performance, this utility model utilizes a semi-circular magnetic ring placed between the primary and secondary film-wound windings to control the leakage inductance to meet the requirements. It can be used more flexibly as a resonant inductor in LLC circuits, accurately control the leakage inductance, solve the defects of existing technologies, and is at the forefront of the industry. Attached Figure Description
[0017] Figure 1 This is a structural diagram of the product of this utility model;
[0018] Figure 2 This is an exploded view of the product of this utility model.
[0019] In the picture:
[0020] 1. Magnetic core; 2. Semi-circular magnetic ring; 3. Frame; 4. Film-coated wire winding. Detailed Implementation
[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0022] Please see Figures 1 to 2 This utility model provides a technical solution:
[0023] An adjustable leakage inductance integrated inductor includes a frame 3, with a film-wound wire winding 4 wound around the outside of the frame 3. The film-wound wire winding 4 is multi-stranded, each film-wound wire winding 4 is multi-stage, and a semi-circular magnetic ring 2 is installed between the primary and secondary stages of the film-wound wire winding 4.
[0024] As an embodiment of this utility model, as shown in the figure, each of the membrane-coated wire windings 4 is wound on two symmetrical winding slots. The winding slots are formed on the frame 3 and can separate the primary and secondary windings of the membrane-coated wire windings 4. The winding slots on two adjacent membrane-coated wire windings 4 are separated and hollow. Thermally conductive adhesive is poured into the hollow area to form insulation and heat conduction, so that insulation is formed between two adjacent membrane-coated wire windings 4, and the heat generated by the operation of the membrane-coated wire windings 4 can be conducted and dissipated, thereby reducing the temperature rise of the transformer.
[0025] As an embodiment of this utility model, as shown in the figure, the semicircular magnetic ring 2 is used to control the size of the leakage inductance. The semicircular magnetic ring 2 controls the size of the leakage inductance by changing its external size. The leakage inductance is used as a resonant inductor in an LLC circuit. That is, the semicircular magnetic ring 2 is placed between the primary and secondary film-wound windings 4 to control the size of the leakage inductance to meet the requirements. It can be used more flexibly as a resonant inductor in an LLC circuit, can accurately control the leakage inductance, solve the defects of the prior art, and reduce costs.
[0026] As an embodiment of this utility model, as shown in the figure, multiple strands of the membrane-wrapped wire winding 4 are wound on the winding groove, and the winding groove is led out at both ends of each group of membrane-wrapped wire winding 4. The part of the membrane-wrapped wire winding 4 leading out of the winding groove serves as a pin, and the pin is fixed on the skeleton 3.
[0027] The frame 3 has magnetic cores 1 installed at both ends. The magnetic cores 1 are semi-enclosed PQ magnetic cores and are in the shape of a ring. The film-wrapped wire winding 4 is wound around the inner circumference of the magnetic core 1.
[0028] The size of the semi-circular magnetic ring 2 can be freely adjusted. The magnetic core 1, the semi-circular magnetic ring 2, the frame 3, and the film-coated wire winding 4 together form a transformer with a simple structure. The film-coated wire winding 4 is wound onto the frame 3 by an automated device. Then, one end of the film-coated wire winding 4 leading out from the winding slot is soldered as a pin and the pin is soldered onto the frame 3. The magnetic core 1 is made of ferric oxide, manganese tetroxide, zinc oxide, etc. The magnetic core 1 is divided into three parts: the upper magnetic core, the lower magnetic core, and the middle sheet magnetic ring. The frame 3 is the iron core column of the transformer. The semi-circular magnetic ring 2 is used to control the magnetic flux of the primary and secondary windings, thereby controlling the leakage inductance.
[0029] The winding method of the membrane-wrapped wire winding 4 is as follows: The membrane-wrapped wire winding 4 adopts the sandwich winding method, in which the primary coil and the secondary coil of the membrane-wrapped wire winding 4 are wound alternately and layered on the winding slot. By making the primary and secondary coils tightly coupled and staggered, the magnetic field can pass through the primary and secondary coils more fully at the same time, which greatly reduces the "leakage" magnetic flux that only links with a single winding, thereby effectively reducing leakage inductance.
[0030] Its coil adopts a membrane wrapping method, so that there is a membrane as insulation between the wires, avoiding the problem of short circuit between windings. Furthermore, the winding slots on the two adjacent membrane-wound windings 4 are separated and hollow, and the hollow area is filled with thermally conductive adhesive. The thermally conductive adhesive fills the hollow area to form insulation and heat conduction, so that the two adjacent membrane-wound windings 4 are insulated from each other, and the heat generated by the membrane-wound windings 4 can be conducted and dissipated, thereby reducing the temperature rise of this transformer.
[0031] In traditional LLC circuits, the transformer and resonant inductor are separate components, resulting in relatively high manufacturing costs. However, this transformer structure, through a customized frame 3, eliminates the independent resonant inductor in traditional LLC circuits by coupling the primary and secondary windings, using the transformer leakage inductance as the resonant inductor. This saves resources. However, the leakage inductance is controlled by the direct distance between the primary and secondary windings, which increases the manufacturing difficulty and leakage inductance defect rate. The leakage inductance can be controlled as the resonant inductor of the LLC circuit. Through the special design of the frame 3, plus the semi-circular magnetic ring 2, the leakage inductance can be flexibly controlled, perfectly solving this problem and technical difficulty, and making it more suitable for the use of various leakage inductance size modes in LLC circuits.
[0032] From a cost perspective, this transformer structure integrates the inductance of the resonant inductor required in LLC circuits, reducing material costs and overall material costs.
[0033] In terms of performance, this structure utilizes a semi-circular magnetic ring 2 placed between the primary and secondary film-wound windings 4 to control the leakage inductance to meet the requirements. It can be used more flexibly as a resonant inductor in LLC circuits, accurately control the leakage inductance, solve the defects of existing technologies, and is among the best in the industry.
[0034] Working principle: The magnetic core 1, semi-circular magnetic ring 2, frame 3, and film-coated wire winding 4 together form a transformer with a simple structure. The film-coated wire winding 4 is wound onto the frame 3 by automated equipment. Then, one end of the film-coated wire winding 4 leading out from the winding slot is soldered as a pin and the pin is soldered onto the frame 3. The magnetic core 1 is made of ferric oxide, manganese tetroxide, zinc oxide, etc. The magnetic core 1 is divided into three parts: upper magnetic core, lower magnetic core, and middle sheet magnetic ring. The frame 3 is the iron core column of the transformer. The semi-circular magnetic ring 2 is used to control the magnetic flux of the primary and secondary windings, thereby controlling the leakage inductance.
[0035] The winding method of the membrane-wrapped wire winding 4 is as follows: The membrane-wrapped wire winding 4 adopts the sandwich winding method, in which the primary coil and the secondary coil of the membrane-wrapped wire winding 4 are wound alternately and layered on the winding slot. By making the primary and secondary coils tightly coupled and staggered, the magnetic field can pass through the primary and secondary coils more fully at the same time, which greatly reduces the "leakage" magnetic flux that only links with a single winding, thereby effectively reducing leakage inductance.
[0036] Its coil adopts a membrane wrapping method, so that there is a membrane as insulation between the wires, avoiding the problem of short circuit between windings. Furthermore, the winding slots on the two adjacent membrane-wound windings 4 are separated and hollow, and the hollow area is filled with thermally conductive adhesive. The thermally conductive adhesive fills the hollow area to form insulation and heat conduction, so that the two adjacent membrane-wound windings 4 are insulated from each other, and the heat generated by the membrane-wound windings 4 can be conducted and dissipated, thereby reducing the temperature rise of this transformer.
[0037] In traditional LLC circuits, the transformer and resonant inductor are separate components, resulting in relatively high manufacturing costs. However, this transformer structure, through a customized frame 3, eliminates the independent resonant inductor in traditional LLC circuits by coupling the primary and secondary windings, using the transformer leakage inductance as the resonant inductor. This saves resources. However, the leakage inductance is controlled by the direct distance between the primary and secondary windings, which increases the manufacturing difficulty and leakage inductance defect rate. The leakage inductance can be controlled as the resonant inductor of the LLC circuit. Through the special design of the frame 3, plus the semi-circular magnetic ring 2, the leakage inductance can be flexibly controlled, perfectly solving this problem and technical difficulty, and making it more suitable for the use of various leakage inductance size modes in LLC circuits.
[0038] From a cost perspective, this transformer structure integrates the inductance of the resonant inductor required in LLC circuits, reducing material costs and overall material costs.
[0039] In terms of performance, this structure utilizes a semi-circular magnetic ring 2 placed between the primary and secondary film-wound windings 4 to control the leakage inductance to meet the requirements. It can be used more flexibly as a resonant inductor in LLC circuits, accurately control the leakage inductance, solve the defects of existing technologies, and is among the best in the industry.
[0040] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. An adjustable leakage inductance integrated inductor, comprising a frame (3), characterized in that: The skeleton (3) is wrapped with a membrane-covered wire winding (4) on the outside. The membrane-covered wire winding (4) is multi-stranded, and each membrane-covered wire winding (4) is multi-level. A semi-circular magnetic ring (2) is installed between the primary and secondary of the membrane-covered wire winding (4).
2. The adjustable leakage inductance integrated inductor according to claim 1, characterized in that: Each of the membrane-coated wire windings (4) is wound on two symmetrical winding slots. The winding slots are opened on the skeleton (3). The winding slots can separate the primary and secondary windings of the membrane-coated wire windings (4). The winding slots on two adjacent membrane-coated wire windings (4) are separated and are hollow areas. The hollow areas are filled with thermally conductive adhesive.
3. The adjustable leakage inductance integrated inductor according to claim 2, characterized in that: The semicircular magnetic ring (2) is used to control the size of the leakage inductance. The semicircular magnetic ring (2) controls the size of the leakage inductance by changing the size of the semicircular magnetic ring (2). The leakage inductance is used as a resonant inductor in an LLC circuit.
4. An adjustable leakage inductance integrated inductor according to claim 3, characterized in that: Multiple strands of the membrane-coated wire winding (4) are wound on the winding groove, and the winding groove is led out at both ends of each group of membrane-coated wire winding (4). The part of the membrane-coated wire winding (4) leading out of the winding groove serves as a pin, and the pin is fixed on the skeleton (3).
5. An adjustable leakage inductance integrated inductor according to claim 4, characterized in that: The skeleton (3) has magnetic cores (1) installed at both ends. The magnetic cores (1) are semi-enclosed PQ magnetic cores. The magnetic cores (1) are in the shape of a ring. The film-wrapped wire winding (4) is wound around the inner circumference of the magnetic cores (1).
6. An adjustable leakage inductance integrated inductor according to claim 5, characterized in that: The size of the semi-circular magnetic ring (2) can be freely adjusted.