A low-loss low-temperature-rise large-power differential-mode inductor

Abstract

The utility model relates to technical field of electronic component discloses a kind of low-loss low temperature rise class high-power differential mode inductor, including bottom plate, the right side of the bottom plate is fixedly connected with shell, the right side of the bottom plate is provided with electrical mechanism, the electrical mechanism is used for the inductance implementation of device, the top and bottom of the shell are provided with closed mechanism, the closed mechanism is used for the closed protection of device, the electrical mechanism includes multiple magnetic cores, the left side of multiple magnetic cores is fixedly connected in the right side of bottom plate, multiple magnetic cores are all used U-shaped structure. In the utility model, adjust magnetic core to form hollow channel relatively in inside, copper foil winding channel forms loop, copper strip connects copper foil and is connected to external circuit through connecting hole, current enters copper foil and produces magnetic field through copper strip, magnetic core concentrates magnetic field, aluminum alloy shell reduces loss and heat dissipation, reduce magnetic field leakage and energy loss, accelerate heat dissipation, guarantee inductor low-loss low temperature rise operation.

Description

Technical Field

[0001] This utility model relates to the field of electronic component technology, and in particular to a low-loss, low-temperature rise, high-power differential mode inductor. Background Technology

[0002] Differential-mode inductors are inductive components that suppress differential-mode interference. When operating, they allow normal differential-mode signals to pass through while creating high impedance to differential-mode interference currents generated by load changes and power supply noise in the circuit, thus hindering their propagation. They are used in power supply filtering and motor drive circuits to improve the electromagnetic compatibility of equipment.

[0003] In high-power scenarios, ordinary differential-mode inductors have high losses, which can cause severe heat generation, waste energy, and even overheat damage. Low-loss design can reduce energy consumption, lower temperature rise, and ensure stable operation, while high-power characteristics can meet the requirements of high current.

[0004] During circuit operation, irregular changes in current and external electromagnetic radiation can generate interference currents in the circuit. These interference currents can affect the normal operation of electronic components in the circuit and cause distortion in circuit signal transmission. In existing technologies, differential mode inductors are used. Through their internal magnetic core and windings, differential mode inductors can suppress differential mode interference currents in the circuit, hindering the propagation of interference currents in the circuit and reducing the impact of interference currents on other electronic components. However, in actual use, when the inductor is energized, the resistance of the windings will generate Joule losses, resulting in excessive operating losses of the differential mode inductor and affecting the stability of the inductor's operation. Utility Model Content

[0005] To overcome the above shortcomings, this utility model provides a low-loss, low-temperature rise, high-power differential-mode inductor, aiming to improve the problem in the prior art where the winding resistance generates Joule losses when the inductor is energized, resulting in excessive operating losses of the differential-mode inductor and affecting the stability of the inductor's operation.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a low-loss, low-temperature rise, high-power differential mode inductor, comprising a base plate, a housing fixedly connected to the right side of the base plate, an electrical mechanism provided on the right side of the base plate, the electrical mechanism being used for the inductance of the device, and a sealing mechanism being provided at the top and bottom of the housing, the sealing mechanism being used for the sealing and protection of the device; The electrical mechanism includes multiple magnetic cores, the left sides of which are fixedly connected to the right side of the base plate. The multiple magnetic cores adopt a U-shaped structure, and the inner sides of the multiple magnetic cores are placed opposite each other, forming two hollow channels between the multiple magnetic cores. Copper foil is wound around the inner side of the two hollow channels. Two copper strips are fixedly connected to the top right side of the copper foil, and connection holes are opened on the right side of the two copper strips.

[0007] As a further description of the above technical solution: The enclosure mechanism includes two side plates, which are respectively disposed at the top and bottom of the outer shell. Multiple bolts are threadedly connected to the outer sides of both side plates. Multiple threaded holes are provided at the top and bottom of the outer shell. The multiple bolts pass through the two side plates respectively and are threadedly connected to the top and bottom of the outer shell respectively.

[0008] As a further description of the above technical solution: The corners of the base plate are all rounded, and multiple mounting holes are provided on the top and bottom of the outer side of the base plate.

[0009] As a further description of the above technical solution: The outer shell is made of aluminum alloy and has a thickness of 2.8mm-3.2mm. The top and bottom of the outer shell are bent inward, and preferably, the thickness is 3mm.

[0010] As a further description of the above technical solution: All of the magnetic cores are made of iron-nickel material, and the edges of all of the magnetic cores are rounded.

[0011] As a further description of the above technical solution: The thickness of the copper foil is set to 0.38mm-0.42mm, and the number of turns of the copper foil is set to 14. Preferably, the thickness is set to 0.4mm.

[0012] As a further description of the above technical solution: The bolts and threaded holes are arranged at equal intervals, and the bolts are symmetrically distributed along the two sides of the two side plates.

[0013] As a further description of the above technical solution: The height of the base plate is set to 514mm-516mm, and the width of the base plate is set to 175mm-177mm. Preferably, the height and width are set to 515mm and 176mm, respectively.

[0014] This utility model has the following beneficial effects: 1. In this utility model, the magnetic core is adjusted to form a hollow channel on the inner side, and the copper foil is wound around the channel to form a circuit. The copper strip is connected to the copper foil and connected to the external circuit through the connecting hole. The current enters the copper foil through the copper strip to generate a magnetic field. The magnetic core concentrates the magnetic field. The aluminum alloy shell reduces heat loss and reduces magnetic field leakage and energy loss, accelerates heat dissipation, and ensures that the inductor operates with low loss and low temperature rise.

[0015] 2. In this utility model, the side plates are respectively placed at the top and bottom of the outer shell. The position is adjusted to cover the opening to form a seal. The bolts pass through the side plates and are screwed into the threaded holes of the outer shell. The bolts are symmetrically and equidistantly arranged to fix the side plates. During maintenance, the bolts are turned counterclockwise to disengage them from the threaded holes. The side plates are removed to expose the electrical mechanism. After maintenance, the side plates are reinstalled and the bolts are tightened to achieve internal sealing protection of the outer shell, prevent dust and moisture from entering, and ensure the safety of the electrical mechanism components. Attached Figure Description

[0016] Figure 1 This is a perspective view of a low-loss, low-temperature rise, high-power differential mode inductor proposed in this utility model. Figure 2 This is a front view of a low-loss, low-temperature rise, high-power differential mode inductor proposed in this utility model. Figure 3 This is a split view of the magnetic core in a low-loss, low-temperature rise, high-power differential mode inductor proposed in this utility model. Figure 4 This is a split view of the copper foil in a low-loss, low-temperature rise, high-power differential mode inductor proposed in this utility model. Figure 5 for Figure 4 Enlarged view of point A in the middle.

[0017] Legend: 1. Base plate; 2. Outer shell; 3. Electrical mechanism; 31. Magnetic core; 32. Copper foil; 33. Copper strip; 34. Connecting hole; 4. Sealing mechanism; 41. Side plate; 42. Bolt; 43. Threaded hole; 5. Mounting hole. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings. 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. Reference Figures 1-5This utility model provides an embodiment of a low-loss, low-temperature rise, high-power differential mode inductor, including a base plate 1. The corners of the base plate 1 are all rounded. Multiple mounting holes 5 are provided on the top and bottom of the outer side of the base plate 1. The height of the base plate 1 is set to 515mm, and the width of the base plate 1 is set to 176mm. A housing 2 is fixedly connected to the right side of the base plate 1. The housing 2 is made of aluminum alloy and has a thickness of 3mm. The top and bottom of the housing 2 are bent inward. An electrical mechanism 3 is provided on the right side of the base plate 1. The electrical mechanism 3 is used to realize the inductance of the device. A sealing mechanism 4 is provided on the top and bottom of the housing 2. The sealing mechanism 4 is used for the sealing and protection of the device. The electrical mechanism 3 includes multiple magnetic cores 31, all of which are made of iron-nickel material and have rounded edges. The left sides of the multiple magnetic cores 31 are fixedly connected to the right side of the base plate 1. The multiple magnetic cores 31 adopt a U-shaped structure and are placed opposite each other on their inner sides. Two hollow channels are formed between the multiple magnetic cores 31. Copper foil 32 is wound around the inner side of the two hollow channels. The thickness of the copper foil 32 is set to 0.4 mm and the number of turns of the copper foil 32 is set to 14. Two copper strips 33 are fixedly connected to the top right side of the copper foil 32. Each of the two copper strips 33 has a connection hole 34 on its right side. Specifically, the base plate 1 provides the mounting foundation, the outer shell 2 provides protection and heat dissipation, the electrical mechanism 3 performs the inductance function, and the enclosure mechanism 4 ensures the sealing performance; The inductor is assembled to form a magnetic field base through the magnetic core 31 of the electrical mechanism 3. The left side of the multiple magnetic cores 31 of the electrical mechanism 3 is fixedly connected to the right side of the base plate 1. The magnetic cores 31 adopt a U-shaped structure and have rounded edges. The inner sides of the multiple magnetic cores 31 are placed opposite each other. When assembling the electrical mechanism 3, the left side of each magnetic core 31 is first attached to the right side of the base plate 1. The magnetic cores 31 and the base plate 1 are fixed by the connector to ensure that the magnetic cores 31 will not be displaced. Then the position of the multiple magnetic cores 31 is adjusted so that the inner sides of all magnetic cores 31 are opposite each other. Two hollow channels are formed between adjacent magnetic cores 31. The U-shaped magnetic cores 31 construct a complete magnetic circuit frame by being placed opposite each other. The inductor constructs a current path by winding the copper foil 32 of the electrical mechanism 3. The copper foil 32 of the electrical mechanism 3 is wound inside two hollow channels. When winding the copper foil 32, one end of the copper foil 32 is fixed to the inner edge of one of the hollow channels. The copper foil 32 is wound evenly along the circumferential direction of the hollow channel to ensure that the copper foil 32 fits tightly against the inner side of the channel without overlap or gap. After winding, the other end of the copper foil 32 is fixed so that the copper foil 32 forms a closed conductive loop inside the two hollow channels. Two copper strips 33 are fixedly connected to the top right side of the copper foil 32. The two copper strips 33 have connection holes 34 on their right sides. The copper strips 33 can be connected to the external circuit through the connection holes 34 so that the external current can be transmitted to the copper foil 32 through the copper strips 33, thus realizing the construction of the current path. The inductor achieves its inductance function through the cooperation of the magnetic core 31 and copper foil 32 in the electrical mechanism 3. When external current is transmitted to the copper strip 33 through the connection hole 34 and then to the copper foil 32, the current flows in the loop formed by the copper foil 32. The flowing current generates a magnetic field around the copper foil 32. Since the copper foil 32 is wound inside the hollow channel formed by the magnetic core 31, and the magnetic core 31 is made of iron-nickel material with high magnetic permeability, it can concentrate the magnetic field generated by the copper foil 32 in the magnetic circuit constructed by the magnetic core 31, reduce magnetic field leakage, and improve magnetic field utilization. The relative placement of the U-shaped magnetic core 31 makes the magnetic field form a closed loop inside the magnetic core 31, which enhances the magnetic field strength. When the current changes, the magnetic field changes accordingly, generating an induced electromotive force in the copper foil 32, which opposes the change of current and realizes the inductance function of the inductor. The inductor reduces losses and temperature rise through the material and structural design of the electrical mechanism 3. The magnetic core 31 is made of iron-nickel material, which has low hysteresis loss characteristics and can reduce energy loss caused by hysteresis during magnetic field changes. The copper foil 32 has excellent conductivity, which can reduce resistance loss when current passes through and reduce heat generated by Joule effect. The outer shell 2 is made of aluminum alloy, which has good thermal conductivity and can quickly conduct the heat generated by the electrical mechanism 3 to the external environment. Combined with the inward bending structure of the top and bottom of the outer shell 2, the heat dissipation area is increased and the heat dissipation is accelerated, so as to achieve the inductor's low loss and low temperature rise operation effect.

[0019] Reference Figures 1-3 The closing mechanism 4 includes two side plates 41, which are respectively disposed at the top and bottom of the outer shell 2. Multiple bolts 42 are threadedly connected to the outer sides of the two side plates 41. Multiple threaded holes 43 are provided at the top and bottom of the outer shell 2. The multiple bolts 42 pass through the two side plates 41 respectively, and are threadedly connected to the top and bottom of the outer shell 2 respectively. The multiple bolts 42 and the multiple threaded holes 43 are arranged at equal intervals, and the multiple bolts 42 are symmetrically distributed along the two sides of the two side plates 41. Specifically, the inductor is initially sealed by the side plate 41 of the sealing mechanism 4 in cooperation with the housing 2. The two side plates 41 of the sealing mechanism 4 are respectively set at the top and bottom of the housing 2. When assembling the sealing mechanism 4, one side plate 41 is first aligned with the top of the housing 2 and the position of the side plate 41 is adjusted so that the side plate 41 completely covers the opening area at the top of the housing 2. Then the other side plate 41 is aligned with the bottom of the housing 2 and the position is adjusted in the same way so that the side plate 41 covers the opening area at the bottom of the housing 2. The two side plates 41 block the opening of the housing 2 from the top and bottom sides respectively, forming an initial shielding of the electrical mechanism 3 inside the housing 2, thereby sealing the opening of the housing 2. The inductor is fixed to the side plate 41 by the bolts 42 and threaded holes 43 of the sealing mechanism 4. Multiple bolts 42 of the sealing mechanism 4 are threaded to the outside of the side plate 41. Multiple threaded holes 43 are provided on the top and bottom of the housing 2. The bolts 42 pass through the side plate 41 and are threaded to the threaded holes 43. The bolts 42 and the threaded holes 43 are arranged at equal intervals. The bolts 42 are symmetrically distributed along both sides of the side plate 41. When fixing the side plate 41, each bolt 42 is aligned with the preset hole on the outside of the side plate 41. The bolt 42 is rotated clockwise so that the bolt 42 passes through the side plate 41 and is gradually screwed into the corresponding threaded hole 43 in the housing 2. The bolt 42 is rotated continuously until the head of the bolt 42 is tightly fitted to the outside of the side plate 41. At this time, the side plate 41 is firmly fixed to the top and bottom of the housing 2 and cannot be displaced, thus achieving a stable connection between the side plate 41 and the housing 2. The inductor ensures uniform sealing through the symmetrical distribution and equidistant arrangement of the sealing mechanism 4. Multiple bolts 42 are symmetrically distributed along both sides of the side plate 41 and are equidistant from the threaded holes 43. During the fixing of the side plate 41, the symmetrically distributed bolts 42 can make the force on both sides of the side plate 41 balanced, preventing the side plate 41 from tilting due to excessive force on one side. The equidistant arrangement of bolts 42 and threaded holes 43 ensures that the pressure between the side plate 41 and the outer shell 2 is evenly distributed, eliminating the gap between the side plate 41 and the outer shell 2, preventing external dust and moisture from entering the interior of the outer shell 2 through the gap and contacting the magnetic core 31 and copper foil 32 of the electrical mechanism 3, thus achieving sealing protection inside the outer shell 2. The inductor's easy maintenance is ensured by the disassembly and assembly structure of the enclosed mechanism 4. When the electrical mechanism 3 needs to be inspected and maintained, the bolt 42 is turned counterclockwise to gradually disengage the bolt 42 from the threaded hole 43 of the housing 2 until the bolt 42 is completely removed from the outside of the side plate 41. Then, the side plate 41 is removed from the top and bottom of the housing 2, and the electrical mechanism 3 inside the housing 2 is fully exposed. The magnetic core 31, copper foil 32, and copper strip 33 can be directly inspected and repaired. After maintenance, the side plate 41 is reinstalled and the bolt 42 is tightened according to the original steps to restore the housing 2 to its closed state, thus realizing convenient maintenance of the inductor.

[0020] Working principle: Assemble the electrical mechanism 3 by attaching the left sides of multiple magnetic cores 31 one by one to the right side of the base plate 1, ensuring that the left side of each magnetic core 31 is completely attached to the right side surface of the base plate 1, so that the inner sides of all magnetic cores 31 are completely opposite, and the ends of adjacent magnetic cores 31 are aligned, ensuring that two hollow channels of uniform size are formed between adjacent magnetic cores 31. Then, fix one end of the copper foil 32 to the inner edge of one of the hollow channels by welding and snapping, keeping the tension of the copper foil 32 uniform, and slowly wind the copper foil 32 along the circumferential direction of the hollow channel, ensuring that the copper foil 32 is tightly attached to the inner side of the channel without overlap or gaps. After winding, fix the other end of the copper foil 32 in the same way, so that the copper foil 32 forms a complete closed conductive circuit inside the two hollow channels. Finally, fix the left ends of the two copper strips 33 to the top right side of the copper foil 32 by welding, ensuring that the copper strips 33 and the copper foil 32 have good conductivity, and the assembly of the electrical mechanism 3 is completed. Assemble the closing mechanism 4. Align the inner side of one of the side plates 41 with the top of the outer shell 2. Adjust the horizontal position of the side plate 41 so that it completely covers the opening area at the top of the outer shell 2 and the edge of the side plate 41 is aligned with the bent structure at the top of the outer shell 2. Align the other side plate 41 with the bottom of the outer shell 2 and adjust its position in the same way so that it covers the opening area at the bottom of the outer shell 2. Then align the multiple bolts 42 with the preset holes on the outer side of the two side plates 41 respectively. Starting from one side of the side plate 41, rotate the bolts 42 clockwise so that the bolts 42 slowly pass through the side plate 41 and are gradually screwed into the corresponding threaded holes 43 at the top and bottom of the outer shell 2. Then tighten the remaining bolts 42 in a symmetrical order until the heads of all bolts 42 are tightly fitted to the outer side of the side plate 41. At this time, the side plate 41 is firmly fixed to the top and bottom of the outer shell 2 and cannot be displaced. The assembly of the closing mechanism 4 is completed. To install the inductor, place the base plate 1 in the preset installation position, ensuring that the corner rounded corners of the base plate 1 meet the installation requirements. Fix the base plate 1 in the installation position through the multiple mounting holes 5 on the top and bottom of the outer side of the base plate 1. During the fixing process, ensure that the base plate 1 remains horizontal to prevent the inductor from tilting. Then, align the wire terminals of the external circuit with the connection holes 34 on the right side of the copper strip 33. Use a connector to pass through the connection holes 34 and the wire terminals, and tighten to achieve the conductive connection between the external circuit and the copper strip 33. Ensure that the external current can be stably transmitted to the copper foil 32 through the copper strip 33, and complete the inductor installation. External current flows through the connection hole 34 into the copper strip 33, and then through the fixing point between the copper strip 33 and the copper foil 32 to the copper foil 32. The current flows continuously in the closed loop formed by the copper foil 32, generating a magnetic field around the copper foil 32. Since the copper foil 32 is wound inside the hollow channel formed by the magnetic core 31, and the magnetic core 31 is made of iron-nickel material with high magnetic permeability, it can concentrate the magnetic field generated by the copper foil 32 in the magnetic circuit constructed by the magnetic core 31, reducing magnetic field leakage to the outside and improving magnetic field utilization. At the same time, the relative placement of the U-shaped magnetic core 31 makes the magnetic field form a closed loop inside the magnetic core 31, further enhancing the magnetic field. When the external current changes, the magnetic field around the copper foil 32 changes synchronously. The changing magnetic field generates an induced electromotive force in the copper foil 32. The direction of the induced electromotive force is opposite to the direction of the current change, which opposes the change of current and realizes the inductance function of the inductor. The operation of the electrical mechanism 3 will generate heat. The outer shell 2 is made of aluminum alloy, which has good thermal conductivity and can quickly conduct heat from the electrical mechanism 3 to the surface of the outer shell 2. Combined with the structure of the top and bottom of the outer shell 2 bending inward, the contact area between the outer shell 2 and the air is increased, which accelerates the heat dissipation to the external environment and realizes the stable operation of the inductor with low loss and low temperature rise. When maintenance is required, first disconnect the external circuit from the copper strip 33, then use a tool to turn the bolt 42 counterclockwise so that the bolt 42 gradually comes off the threaded hole 43 of the outer shell 2 until all the bolts 42 are completely removed from the outside of the side plate 41. Then, hold the edge of the side plate 41 and remove the side plate 41 from the top and bottom of the outer shell 2. The electrical mechanism 3 inside the outer shell 2 is fully exposed, and you can directly check whether the magnetic core 31 is loose, whether the copper foil 32 is damaged, and whether the copper strip 33 is firmly connected. Repair and replace any problematic parts. After maintenance, reinstall the side plate 41 on the top and bottom of the outer shell 2 according to the original steps, align the bolts 42 with the threaded hole 43, and tighten the bolts 42 clockwise to restore the closed state of the outer shell 2.

[0021] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A low-loss, low-temperature-rise, high-power differential-mode inductor of the low-profile type comprising a base plate (1), characterized in that: The base plate (1) is fixedly connected to the right side of the outer shell (2), and the base plate (1) is provided with an electrical mechanism (3). The electrical mechanism (3) is used for the inductance of the device. The top and bottom of the outer shell (2) are provided with a sealing mechanism (4). The sealing mechanism (4) is used for the sealing and protection of the device. The electrical mechanism (3) includes multiple magnetic cores (31). The left side of each of the multiple magnetic cores (31) is fixedly connected to the right side of the base plate (1). Each of the multiple magnetic cores (31) adopts a U-shaped structure. The inner sides of the multiple magnetic cores (31) are placed opposite each other. Two hollow channels are formed between the multiple magnetic cores (31). Copper foil (32) is wound around the inner side of the two hollow channels. Two copper strips (33) are fixedly connected to the top right side of the copper foil (32). A connection hole (34) is opened on the right side of each of the two copper strips (33).

2. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 1, characterized in that: The closing mechanism (4) includes two side plates (41), which are respectively disposed at the top and bottom of the outer shell (2). Multiple bolts (42) are threadedly connected to the outer sides of the two side plates (41). Multiple threaded holes (43) are provided at the top and bottom of the outer shell (2). The multiple bolts (42) pass through the two side plates (41) respectively, and are threadedly connected to the top and bottom of the outer shell (2).

3. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 1, characterized in that: The corners of the base plate (1) are all rounded, and multiple mounting holes (5) are provided on the top and bottom of the outer side of the base plate (1).

4. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 1, characterized in that: The outer shell (2) is made of aluminum alloy and the thickness of the outer shell (2) is set at 2.8mm-3.2mm. The top and bottom of the outer shell (2) are bent inward.

5. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 1, characterized in that: All of the magnetic cores (31) are made of iron-nickel material, and the edges of all of the magnetic cores (31) are rounded.

6. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 1, characterized in that: The thickness of the copper foil (32) is set to 0.38mm-0.42mm, and the number of turns of the copper foil (32) is set to 14.

7. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 2, characterized in that: The multiple bolts (42) and multiple threaded holes (43) are arranged at equal intervals, and the multiple bolts (42) are symmetrically distributed along the two sides of the two side plates (41).

8. A low-loss, low-temperature-rise, high-power differential-mode inductor according to claim 1, characterized in that: The height of the base plate (1) is set to 514mm-516mm, and the width of the base plate (1) is set to 175mm-177mm.

Images