Inductor with flat copper wire and round wire composite winding

Abstract

The utility model discloses a kind of inductors of flat copper wire and round wire composite winding, it is related to the field of inductor manufacturing technology, it includes base, the two sides of base along width direction are glued with baffle, fixedly set with magnetic core on baffle, magnetic core includes two groups of spliced magnetic core, spliced magnetic core includes straight plate part, two plug-in parts and barrier part, plug-in part and barrier part are directly glued with straight plate part, straight plate part is fixedly connected with baffle, two insulating supports are equipped on base, insulating support is opened with through hole along its own axial direction, two plug-in parts are mutually resisted after passing through through hole, the first winding of being formed by flat line is wound around on the surface of insulating support along circumference, the second winding of being formed by round line is wound around on the outside of first winding. The present application has the effect of improving the working efficiency of inductor.

Description

Technical Field

[0001] This utility model relates to the field of inductor manufacturing technology, and in particular to an inductor with a composite winding of flat copper wire and round wire. Background Technology

[0002] Currently, inductors are widely used in power electronic devices that need to handle both high-frequency noise and high current, such as switching power supplies, inverters, and electric drive systems for new energy vehicles. Traditional inductors utilize the phenomenon of electromagnetic induction to generate induced power through the time-varying current, and are an important component of circuits.

[0003] Related technology can be found in Chinese Patent Publication No. CN222720187U, which discloses an inductor. The inductor described in this application includes a first magnetic core, a second magnetic core, a first winding, and a second winding. The first magnetic core includes a substrate and a central post, with the central post vertically disposed on the substrate. The second magnetic core is disposed opposite to the first magnetic core, and the central post is located between the first and second magnetic cores. The first winding is wound around the central post, using flat wire and wound in a flat winding manner. The second winding is wound around the central post along with the first winding, using flat wire and wound in a vertical winding manner. The inductor described in this application has the advantages of optimized dimensions and high production efficiency.

[0004] Regarding the aforementioned technologies, the device uses wire stacking to increase the cross-sectional area to reduce resistance, but the interlayer distributed capacitance leads to a deterioration of insertion loss in the high-frequency band. In addition, amorphous alloy magnetic cores are used to reduce high-frequency eddy currents, but the cross-sectional area of ​​the wires limits the rated current to usually below 5A. Winding flat and round wires in parallel can balance current carrying capacity and high-frequency characteristics, but the contact resistance at the parallel connection point can cause local overheating, affecting the device's performance. Utility Model Content

[0005] To address the aforementioned problems, this application provides an inductor with a composite winding of flat copper wire and round wire.

[0006] This application provides an inductor with a composite winding of flat copper wire and round wire, employing the following technical solution: An inductor with a composite winding of flat copper wire and round wire includes a base. An insulating support is provided on the upper surface of the base. A first winding formed by flat wire is wound around the outside of the insulating support, and a second winding formed by round wire is wound around the outside of the first winding. Baffles are glued to both sides of the upper surface of the base along the width direction. A magnetic core adapted to the insulating support is fixed on each baffle. The magnetic core is parallel to the width direction of the base. A through hole is opened along the axial direction of the insulating support, and the magnetic core passes through the through hole.

[0007] By adopting the above technical solution, under the support of the base, the insulating bracket fixes and limits the first and second windings. The flat wire is wound onto the insulating bracket, which reduces the gap between coil layers to achieve higher space utilization. The round wire is convenient for high-frequency winding, and the distributed capacitance is reduced, making the inductor more adaptable to high-frequency noise suppression. The cooperation between the first and second windings enables the inductor to resolve the contradiction between electrical isolation and magnetic circuit coordination, so that the high-frequency distributed capacitance and high current carrying capacity can be compatible. Under the support of the baffle, the magnetic core supports the insulating bracket through the through hole. After the power is turned on, a magnetic field is generated around the insulating bracket, which helps to improve the working effect of the inductor.

[0008] Optionally, the magnetic core includes two opposing spliced ​​magnetic cores. The spliced ​​magnetic core includes a straight plate portion for connecting the base, two plug-in portions, and a blocking portion. The straight plate portion is parallel to and fixed to the baffle. The two plug-in portions are respectively vertically fixed to both ends of the straight plate portion, and the plug-in portions correspond one-to-one with the insulating brackets. The two plug-in portions at the same end of the two straight plate portions pass through the through holes of the same insulating bracket and abut against each other. The blocking portion is fixed on the side of the straight plate portion connected to the plug-in portion and is located between the two insulating brackets. The two blocking portions abut against each other.

[0009] By adopting the above technical solution, the base supports the plug-in part and the blocking part through the straight plate part, the spliced ​​magnetic core is E-shaped as a whole, and the two spliced ​​magnetic cores work together to form a H-shaped magnetic core. After being powered on, the H-shaped magnetic core forms a closed magnetic circuit structure, which is conducive to improving the effective magnetic permeability.

[0010] Optionally, the baffle is provided with an outer shell, which is fitted onto the outside of the spliced ​​magnetic core.

[0011] By adopting the above technical solution, the baffle supports the outer shell, and the outer shell blocks the internal magnetic field from radiating outward to avoid interfering with the surrounding circuits. At the same time, it reduces the probability that the external electromagnetic field will pass through the magnetic core and affect the operation of the inductor.

[0012] Optionally, the base is provided with bosses at both ends along its length, the bosses are set higher than the base, and the baffle is located between the two bosses and contacts the bosses.

[0013] By adopting the above technical solution, the boss further fixes and limits the displacement of the baffle along the length of the base, which is beneficial to improving the structural stability and performance reliability of the inductor.

[0014] Optionally, a pin corresponding to the boss is fixed vertically below the base, and the end of the pin facing away from the base is a plane.

[0015] By adopting the above technical solution, the pins support the base, and the ends of the round wires can be wound around the pins and energized through the pins, which helps to improve the stability and safety of the inductor's operation.

[0016] Optionally, the upper surface of the base is provided with a groove 1 that is adapted to the lower end of the insulating bracket, and a groove 2 that communicates with the groove 1, the groove 2 being adapted to the second winding.

[0017] By adopting the above technical solution, groove one provides space for the insulating support, and groove two accommodates the part of the second winding that protrudes from the insulating support, which helps to save space and improve the compactness of the inductor structure.

[0018] Optionally, the insulating support is fixed with partitions on both sides along the axial direction, and the first winding and the second winding are both located between the two partitions.

[0019] By adopting the above technical solution, the side partitions limit the displacement of the first winding and the second winding along the axis of the insulating support, so that the first winding and the second winding can be evenly arranged on the surface of the insulating support, reducing the probability of the wire arrangement being skewed or disordered.

[0020] Optionally, the upper and lower surfaces of the partition plate are provided with corresponding openings.

[0021] By adopting the above technical solution, the opening facilitates the disassembly and rewinding of the wire.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. With the support of the base, the insulating bracket fixes and limits the first and second windings. The flat wire is wound onto the insulating bracket, which reduces the gap between coil layers to achieve higher space utilization. The round wire is easy to wind at high frequency, and the distributed capacitance is reduced, making the inductor more suitable for high-frequency noise suppression. The cooperation between the first and second windings solves the contradiction between electrical isolation and magnetic circuit coordination, and makes the high-frequency distributed capacitance and high current carrying capacity compatible. With the support of the baffle, the magnetic core supports the insulating bracket through the through hole. After the power is turned on, a magnetic field is generated around the insulating bracket, which helps to improve the working effect of the inductor. 2. The base supports the insertion part and the blocking part through the straight plate part. The spliced ​​magnetic core is E-shaped as a whole. The two spliced ​​magnetic cores work together to form a H-shaped magnetic core. After being powered on, the H-shaped magnetic core forms a closed magnetic circuit structure, which is beneficial to improving the effective magnetic permeability. 3. The baffle supports the outer casing, which prevents the internal magnetic field from radiating outward and interfering with surrounding circuits. At the same time, it reduces the probability that external electromagnetic fields will pass through the magnetic core and affect the operation of the inductor. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of an inductor with a composite winding of flat copper wire and round wire.

[0024] Figure 2 This is a schematic diagram designed to highlight the spliced ​​magnetic core structure.

[0025] Figure 3 This is a schematic diagram designed to highlight the position of the first winding.

[0026] Figure 4 This is a schematic diagram designed to highlight the positions of groove one and groove two.

[0027] Explanation of reference numerals in the attached drawings: 1. Base; 11. Groove 1; 12. Groove 2; 13. Boss; 14. Pin; 2. Insulating bracket; 21. First winding; 22. Second winding; 23. Partition; 24. Opening; 25. Through hole; 3. Baffle; 4. Magnetic core; 41. Spliced ​​magnetic core; 411. Straight plate section; 412. Insertion section; 413. Barrier section; 42. Outer shell; Detailed Implementation The present application will be further described in detail below with reference to all the accompanying drawings.

[0028] This application discloses an inductor with a composite winding of flat copper wire and round wire. Example

[0029] Reference Figure 1 and Figure 2 An inductor with a composite winding of flat copper wire and round wire includes a base 1. Two baffles 3 are glued to the base 1 and arranged along the length of the base 1. A splicing magnetic core 41 is fixedly connected to the side of the two baffles 3 that are close to each other. The splicing magnetic core 41 includes a straight plate part 411, two plug-in parts 412, and a blocking part 413. The straight plate part 411 is parallel to the baffles 3. The plug-in parts 412 and the blocking part 413 are both fixedly connected to the straight plate part 411. The blocking part 413 is located between the two plug-in parts 412. The splicing magnetic core 41 is E-shaped. The two sets of splicing magnetic cores 41 after assembly cooperate to form a complete magnetic core 4. The magnetic core 4 is H-shaped. After being energized, the H-shaped magnetic core 4 forms a closed magnetic circuit, which is beneficial to improving the effective permeability.

[0030] Reference Figure 1 The outer side of the baffle 3 is provided with a housing 42, which is fitted on the outside of the splicing magnetic core 41. The housing 42 can reduce the interference of the inductor to the external circuit, and at the same time reduce the probability of external electromagnetic fields invading the magnetic core 4 and the coil, affecting the working stability of the inductor.

[0031] Reference Figure 1 Both sides of the upper surface of the base 1 along the length direction are fixedly installed with bosses 13. The bosses 13 are located on both sides of the baffle 3 and are in contact with the baffle 3. The bosses 13 further fix and limit the baffle 3, which helps to improve the structural stability and reliability of the device.

[0032] Reference Figure 1The lower end face of the base 1 is vertically fixed with pins 14 corresponding to the boss 13. The end of the round wire is wound around the pins 14 and energized through the pins 14. The pins 14 support the entire device through the base 1, which helps to improve the stability of the device.

[0033] Reference Figure 2 and Figure 3 The upper surface of the base 1 is provided with an insulating bracket 2 corresponding to the magnetic core 4. The insulating bracket 2 has a through hole 25 along its own axis. The magnetic core 4 passes through the through hole 25 of the corresponding insulating bracket 2 and supports the insulating bracket 2, which helps to improve the working stability of the device. The plug-in parts 412 pass through the through hole 25 of the corresponding insulating bracket 2 and abut against each other. At the same time, the blocking parts 413 abut against each other. The base 1 supports the plug-in parts 412 and the blocking parts 413 through the straight plate part 411.

[0034] Reference Figure 1 and Figure 3 The surface of the insulating support 2 is circumferentially wound with a first winding 21 made of flat wire, and a second winding 22 made of round wire is circumferentially wound outside the first winding 21. In this embodiment, the round wire is wound in three layers and completely covers the first winding 21. The flat wire serves as the base layer to establish the main magnetic field channel, and the round wire layer is used to fine-tune the edge magnetic field distribution. The first winding 21 and the second winding 22 work together to attenuate common-mode noise, which is beneficial to improving the working effect of the inductor.

[0035] Reference Figure 4 The upper surface of the base 1 has a groove 11 that fits the shape of the lower end of the insulating bracket 2, and a groove 12 that communicates with the groove 11. The groove 11 is used to accommodate the lower end of the insulating bracket 2, and the groove 12 is used to accommodate the part of the second winding 22 that protrudes from the surface of the insulating bracket 2, which helps to improve the compactness of the device structure.

[0036] Reference Figure 1 and Figure 3 The insulating support 2 has partitions 23 fixed on both sides along the axial direction. The partitions 23 are parallel to the baffles 3. The first winding 21 and the second winding 22 are located between the two partitions 23. The partitions 23 can shield the first winding 21 and the second winding 22 in the radial direction, so that the first winding 21 and the second winding 22 are arranged compactly and evenly on the surface of the insulating support 2, which helps to reduce the probability of the first winding 21 and the second winding 22 being misaligned or skewed.

[0037] Reference Figure 1 The partition 23 has openings 24 on both sides along the vertical direction, which allows operators to disassemble and rewind the wires on the inductor, thus improving the convenience of wire disassembly.

[0038] The implementation principle of an inductor with a composite winding of flat copper wire and round wire in this application embodiment is as follows: After the device is powered on, the first winding 21 establishes a magnetic field channel, the second winding 22 finely adjusts the edge magnetic field distribution, the base 1 supports the spliced ​​magnetic core 41, the spliced ​​magnetic core 41 passes through the through hole 25 to support the insulating bracket 2, and the E-shaped spliced ​​magnetic cores 41 on both sides abut against each other to form a closed magnetic circuit structure. The first winding 21 and the second winding 22 achieve common mode suppression function through sharing the magnetic circuit. While improving the effective permeability, it realizes the compatibility of high-frequency distributed capacitance and high current carrying capacity, which is beneficial to improving the working effect of the inductor.

[0039] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An inductor with a composite winding of flat copper wire and round wire, comprising a base (1), characterized in that: The upper surface of the base (1) is provided with an insulating support (2). A first winding (21) formed by flat wire is wound around the outside of the insulating support (2), and a second winding (22) formed by round wire is wound around the outside of the first winding (21). Baffles (3) are glued to both sides of the upper surface of the base (1) along the width direction. Each baffle (3) is fixed with a magnetic core (4) that is compatible with the insulating support (2). The magnetic core (4) is parallel to the width direction of the base (1). The insulating support (2) is provided with a through hole (25) along the axial direction. The magnetic core (4) passes through the through hole (25).

2. An inductor with a composite winding of flat copper wire and round wire according to claim 1, characterized in that: The magnetic core (4) includes two opposing spliced ​​magnetic cores (41). The spliced ​​magnetic core (41) includes a straight plate part (411) for connecting the base (1), two plug-in parts (412) and a blocking part (413). The straight plate part (411) is parallel to and fixed to the baffle (3). The two plug-in parts (412) are respectively vertically fixed to both ends of the straight plate part (411), and the plug-in parts (412) correspond one-to-one with the insulating bracket (2). The two plug-in parts (412) at the same end of the two straight plate parts (411) pass through the through hole (25) of the same insulating bracket (2) and abut against each other. The blocking part (413) is fixed on the side of the straight plate part (411) connected to the plug-in part (412) and is located between the two insulating brackets (2). The two blocking parts (413) abut against each other.

3. An inductor with a composite winding of flat copper wire and round wire according to claim 2, characterized in that: The baffle (3) is provided with an outer shell (42) on the outside, and the outer shell (42) is fitted on the outside of the splicing magnetic core (41).

4. An inductor with a composite winding of flat copper wire and round wire according to claim 1, characterized in that: The base (1) has protrusions (13) fixed at both ends along its length. The protrusions (13) are set higher than the base (1). The baffle (3) is located between the two protrusions (13) and contacts the protrusions (13).

5. An inductor with a composite winding of flat copper wire and round wire according to claim 1, characterized in that: The base (1) is vertically fixed with pins (14) corresponding to the boss (13) below it, and the end of the pin (14) away from the base (1) is a plane.

6. An inductor with a composite winding of flat copper wire and round wire according to claim 1, characterized in that: The upper surface of the base (1) is provided with a groove 1 (11) that is adapted to the lower end of the insulating bracket (2), and a groove 2 (12) that is connected to the groove 1 (11) is provided. The groove 2 (12) is adapted to the second winding (22).

7. An inductor with a composite winding of flat copper wire and round wire according to claim 1, characterized in that: The insulating support (2) has partitions (23) fixed on both sides along the axial direction, and the first winding (21) and the second winding (22) are both located between the two partitions (23).

8. An inductor with a composite winding of flat copper wire and round wire according to claim 7, characterized in that: The upper and lower surfaces of the partition (23) are provided with corresponding openings (24).

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