A differential mode inductor

Abstract

This invention discloses a differential mode inductor, comprising a magnetic core, two insulating frames, and a coil. The magnetic core includes an upper yoke, a core post, and a lower yoke, all of which are metal powder pressed parts. The two ends of the core post are connected to the upper and lower yokes respectively along its length. Each insulating frame has mounting holes, and the two ends of the core post pass through these holes. The coil is wound around the outer circumference of the core post and located between the two insulating frames. This invention solves the problem of overheating causing burn-in, resulting in more stable operation of the differential mode inductor.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and in particular to a differential mode inductor. Background Technology

[0002] With the development of the photovoltaic industry, photovoltaic inverters are now operating in parallel on the grid side. The normal operation of this system relies on a highly reliable and efficient power supply system. The voltage conversion of the transformer and the energy storage and filtering function of the inductor directly affect the reliability and stable operation of the converter. Differential-mode inductors not only need strong suppression of differential-mode signals, but also must possess excellent AC / DC superposition capability, high current load capacity, strong anti-saturation capability, and low loss characteristics. Differential-mode inductors are widely used in grid-connected systems, UPS, communication power supplies, and other applications.

[0003] The current market trend is towards lower costs and smaller sizes, leading to the widespread use of silicon steel inductors for AC differential mode. However, in actual operation, due to variations in the power environment, circuit design and system software cannot provide an ideal power frequency environment. When silicon steel inductors operate in environments with high frequencies, harmonics, or distorted waveforms, they can experience localized vibrations and noise. If this continues for too long, it can lead to increased iron losses, higher core temperatures, and even serious problems such as burn-out. Utility Model Content

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a differential mode inductor.

[0005] The solution to the technical problem of this utility model is: A differential-mode inductor, comprising: A magnetic core includes an upper yoke, a core post, and a lower yoke. The upper yoke, the core post, and the lower yoke are all metal powder pressed parts. The two ends of the core post along the length direction are respectively connected to the upper yoke and the lower yoke. Two insulating frames, each of which has a mounting hole, and the two ends of the core column pass through the mounting holes of the two insulating frames respectively; A coil, which is wound around the outer periphery of the core post and located between the two insulating frames.

[0006] This invention has at least the following beneficial effects: by forming a magnetic core by pressing metal powder, the density of the magnetic core can be improved, noise and eddy currents can be effectively suppressed, making the differential mode inductor suitable for high-frequency applications. Moreover, it avoids local vibration of the differential mode inductor, reduces temperature rise, and improves the stability of differential mode inductor operation.

[0007] As a further improvement to the above technical solution, the differential mode inductor also includes an epoxy resin layer, and the two ends of the core column are respectively connected to the upper yoke and the lower yoke through the epoxy resin layer.

[0008] As a further improvement to the above technical solution, the core column is provided in three parallel positions between the upper yoke and the lower yoke, and the coil is provided in three corresponding positions, with each coil corresponding to one of the core columns.

[0009] As a further improvement to the above technical solution, the differential mode inductor also includes two first insulating papers, which are disposed between two adjacent coils, and the two ends of each first insulating paper are respectively connected to the two insulating frames.

[0010] As a further improvement to the above technical solution, the differential mode inductor also includes a second insulating paper, which surrounds the outer periphery of the core post to isolate the core post and the coil.

[0011] As a further improvement to the above technical solution, the core column is cylindrical or cuboid.

[0012] As a further improvement to the above technical solution, the differential mode inductor also includes a base plate, and the magnetic core, the coil and the insulating frame together form an inductor structure. The inductor structure is located above the base plate, and the lower end of the insulating frame is connected to the upper surface of the base plate.

[0013] As a further improvement to the above technical solution, the base plate is provided with at least two wire outlets, and each pair of wire outlets corresponds to a coil. The winding start end and winding end of the coil extend downward from the top of the base plate to the bottom of the base plate through the wire outlets.

[0014] As a further improvement to the above technical solution, the differential mode inductor also includes a support foot, which is connected to the lower surface of the base plate, and the height of the support foot is greater than or equal to 4.5 mm and less than or equal to 5.5 mm.

[0015] As a further improvement to the above technical solution, the differential mode inductor also includes an insulating block, which is disposed on the outside of the inductor structure and connected to the base plate.

[0016] Additional aspects and advantages of this application 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 this application. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly explained below. Obviously, the described drawings are only a part of the embodiments of this utility model, and not all of them. Those skilled in the art can obtain other design schemes and drawings based on these drawings without creative effort.

[0018] Figure 1 This is an exploded view of the magnetic core of the differential mode inductor according to an embodiment of the present invention; Figure 2 This is a front view of the differential mode inductor according to an embodiment of the present invention; Figure 3 This is a side view of the differential mode inductor according to an embodiment of the present invention; Figure 4 This is a top view of the differential mode inductor according to an embodiment of the present invention; Figure 5 This is a bottom view of the base plate of the differential mode inductor according to an embodiment of the present invention.

[0019] Reference numerals: 100, magnetic core; 110, upper yoke; 120, lower yoke; 130, core post; 140, epoxy resin layer; 200, insulating frame; 300, coil; 310, winding start end; 320, winding end; 400, base plate; 410, support foot; 420, wire outlet; 500, first insulating paper. Detailed Implementation

[0020] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0021] In the description of this utility model, the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0022] In the description of this utility model, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. If "first" or "second" is used in the description, it is only for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0023] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0024] Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are all within the scope of protection of this utility model. The various technical features of this utility model can be combined interactively without contradicting each other.

[0025] Reference Figures 1 to 5 This utility model embodiment proposes a differential mode inductor, including a magnetic core 100, an insulating frame 200, and a coil 300, which can overcome the shortcomings of traditional silicon steel inductors such as high-frequency heating, high loss, and high noise, and improve the stability of operation.

[0026] The magnetic core 100 includes an upper yoke 110, a core post 130, and a lower yoke 120. The two ends of the core post 130 along its length are connected to the upper yoke 110 and the lower yoke 120, respectively. Two insulating frames 200 are provided, each with mounting holes. The two ends of the core post 130 pass through the mounting holes of the two insulating frames 200, respectively. The coil 300 is wound around the outer periphery of the core post 130 and positioned between the two insulating frames 200. It is understood that the insulating frames 200 prevent the coil 300 from directly contacting the upper yoke 110 or the lower yoke 120, thus ensuring the performance of the differential mode inductor.

[0027] It is worth noting that the upper yoke 110, core post 130 and lower yoke 120 in this embodiment are formed by pressing metal powder after insulation treatment. They are metal powder pressed parts. The resulting magnetic core 100 has high density and can effectively suppress noise and eddy currents, making it suitable for high-frequency applications.

[0028] In this embodiment, the coil 300 is made of enameled wire and has a winding start end 310 and a winding end end 320 to facilitate connection with other electronic components.

[0029] In some embodiments, the differential mode inductor further includes an epoxy adhesive layer 140, with both ends of the core post 130 connected to the upper yoke 110 and the lower yoke 120 respectively via the epoxy adhesive layer 140. During assembly, a single-component high-temperature epoxy adhesive is applied to the contact surfaces between the upper and lower yokes 120 and the core post 130, and then cured by high-temperature baking using a simple fixture to achieve the assembly and forming of the magnetic core 100. It is understood that by using a direct bottling method, the processing difficulty of the differential mode inductor can be greatly reduced, and processing efficiency improved.

[0030] In some embodiments, three core posts 130 are provided, arranged parallel to each other between the upper yoke 110 and the lower yoke 120. Correspondingly, three coils 300 are provided, with each coil 300 corresponding to one core post 130. It is understood that installing multiple core posts 130 between the upper yoke 110 and the lower yoke 120 satisfies the installation quantity requirements while saving inductor space, making it more convenient for users.

[0031] In this embodiment, each insulating frame 200 is provided with three mounting holes so that the three core posts 130 can pass through and connect to the upper yoke 110 or the lower yoke 120.

[0032] In some embodiments, refer to Figure 4 The differential mode inductor also includes two first insulating papers 500, which are disposed between two adjacent coils 300. Each first insulating paper 500 is connected to two insulating frames 200 at both ends. It can be understood that the first insulating paper 500 can separate two adjacent coils 300, preventing the coils 300 from contacting each other and affecting the performance of the differential mode inductor.

[0033] In some embodiments, the differential mode inductor further includes a second insulating paper disposed around the outer periphery of the core post 130 to isolate the core post 130 and the coil 300, thereby providing insulation between the core post 130 and the coil 300.

[0034] In some embodiments, the core post 130 is pressed into a cylinder or cuboid shape to facilitate the winding of the coil 300 and the assembly of the upper yoke 110 and lower yoke 120. For a cylindrical core post 130, scratches to the enamel layer on the surface of the coil 300 can be avoided, thereby improving the service life and performance of the coil 300. For a cuboid core post 130, the edges of the cuboid are chamfered before use, which also helps prevent damage to the coil 300.

[0035] In some embodiments, the differential mode inductor further includes a base plate 400, a magnetic core 100, a coil 300, and an insulating frame 200 to form an inductor structure. The entire inductor structure is mounted above the base plate 400. The lower end of the insulating frame 200 is connected to the upper surface of the base plate 400, and the winding start end 310 and winding end end 320 of the coil 300 pass downward through the base plate 400, respectively.

[0036] In some embodiments, refer to Figure 5 The base plate 400 is provided with a wire outlet 420. There are multiple wire outlets 420, and the number of wire outlets 420 is even. Each pair of wire outlets 420 corresponds to a coil 300. The winding start end 310 and winding end 320 of the coil 300 extend downward from the top of the base plate 400 to the bottom of the base plate 400 through the wire outlets 420.

[0037] In this embodiment, there are six cable outlets 420, arranged in two rows. Each row of cable outlets 420 has three cable outlets 420 arranged in the left-right direction. The center distance between two adjacent cable outlets 420 in the same row is greater than or equal to 31.5 mm and less than or equal to 32.5 mm. Each cable outlet 420 is a square hole with a side length of 6 mm. The machining error of the square hole size is within 0.8 mm. The two outlets 420 corresponding to the beginning end 310 and the end end 320 of the same coil 300 are located in two rows respectively. The distance between the two outlets 420 in the left-right direction is greater than or equal to 23.5 mm and less than or equal to 24.5 mm. The distance between the two outlets 420 in the front-back direction is greater than or equal to 32.5 mm and less than or equal to 33.5 mm.

[0038] In some embodiments, the differential mode inductor further includes a support leg 410 connected to the lower surface of the base plate 400. The height of the support leg 410 is greater than or equal to 4.5 mm and less than or equal to 5.5 mm. The support leg 410 is used to support the base plate 400, and after the base plate 400 is installed with other components, it facilitates the extension of the winding start end 310 and winding end end 320 of the coil 300, making installation easier.

[0039] In some embodiments, the differential mode inductor further includes an insulating block disposed on the outside of the inductor structure and connected to the upper surface of the base plate 400. It is understood that the insulating block is used to protect and isolate the outside of the coil 300, preventing the coil 300 from directly contacting other components and affecting the performance of the differential mode inductor after the differential mode inductor of this embodiment is installed.

[0040] The differential mode inductor of this embodiment solves the problems of difficult assembly and low efficiency of traditional silicon steel lamination methods, reducing processing difficulty and increasing processing efficiency by 20%. Furthermore, the differential mode inductor of this embodiment solves the problem of limited applicable frequencies of traditional silicon steel inductors, achieving the effects of noise reduction, loss reduction, and high-frequency overheating, resulting in more stable operation and a 10% reduction in temperature rise.

[0041] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.

Claims

1. A differential-mode inductor, characterized in that, include: A magnetic core includes an upper yoke, a core post, and a lower yoke. The upper yoke, the core post, and the lower yoke are all metal powder pressed parts. The two ends of the core post along the length direction are respectively connected to the upper yoke and the lower yoke. Two insulating frames, each of which has a mounting hole, and the two ends of the core column pass through the mounting holes of the two insulating frames respectively; A coil, which is wound around the outer periphery of the core post and located between the two insulating frames.

2. The differential-mode inductor according to claim 1, characterized in that, The differential mode inductor also includes an epoxy resin layer, and the two ends of the core post are respectively connected to the upper yoke and the lower yoke through the epoxy resin layer.

3. The differential-mode inductor according to claim 1, characterized in that, The core column is provided in three parallel positions between the upper yoke and the lower yoke. The coil is provided in three corresponding positions, with each coil corresponding to one of the core columns.

4. The differential-mode inductor according to claim 3, characterized in that, The differential mode inductor also includes two first insulating papers, which are disposed between two adjacent coils, and the two ends of each first insulating paper are respectively connected to two insulating frames.

5. The differential-mode inductor according to claim 1, characterized in that, The differential mode inductor also includes a second insulating paper that surrounds the outer periphery of the core post to isolate the core post from the coil.

6. The differential-mode inductor according to claim 1, characterized in that, The core column is cylindrical or cuboid.

7. The differential-mode inductor according to claim 1, characterized in that, The differential mode inductor also includes a base plate. The magnetic core, the coil, and the insulating frame together form an inductor structure. The inductor structure is located above the base plate, and the lower end of the insulating frame is connected to the upper surface of the base plate.

8. The differential-mode inductor according to claim 7, characterized in that, The base plate is provided with at least two wire outlets, and each pair of wire outlets corresponds to a coil. The winding start end and winding end of the coil extend downward from the top of the base plate to the bottom of the base plate through the wire outlets.

9. The differential-mode inductor according to claim 8, characterized in that, The differential mode inductor also includes a support foot, which is connected to the lower surface of the base plate, and the height of the support foot is greater than or equal to 4.5 mm and less than or equal to 5.5 mm.

10. The differential-mode inductor according to claim 7, characterized in that, The differential mode inductor also includes an insulating block, which is located on the outside of the inductor structure and connected to the base plate.

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