A novel PFC inductor structure

Abstract

The utility model discloses a novel PFC inductance structure relates to inductance technical field, including the upper magnetic core and lower magnetic core and left wire frame and right wire frame of opposite setting, the both sides of the opposite side of upper magnetic core and lower magnetic core form the winding area, and two winding areas all are provided with the upper core column and lower core column respectively extending from upper magnetic core and lower magnetic core, and the upper core column and lower core column are provided with the magnetic core air gap between, left wire frame and right wire frame are set in two winding areas and are set in the outside of upper core column and lower core column, and left wire frame and right wire frame are respectively wound with left coil and right coil, be provided with the baffle on lower core column, be provided with the magnetic sheet on the baffle, the stacking of baffle and magnetic sheet in the magnetic core air gap, utilize the space of baffle division magnetic core air gap, disperse the magnetic flux, avoid the magnetic flux concentrated across, avoid causing the local serious heating, promote the long -term work stability of inductance, two windings are integrated in a group upper magnetic core and lower magnetic core among, reduce the area of occupation on the PCB board.

Description

Technical Field

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

[0002] PFC (Power Factor Correction) circuits improve the power factor of a circuit through circuit structure. PFC circuits are commonly used in power supply products or power modules in electronic devices. PFC inductors are inductors used in PFC circuits; their main function is to improve the power factor of AC power supplies, reduce harmonic pollution on the power grid, and improve energy efficiency.

[0003] PFC inductors have a core air gap between the cores; however, due to the concentrated crossing of the magnetic flux path through the core air gap, it is easy to cause severe local heat generation. Furthermore, PFC circuits typically require multiple PFC inductors to work together to achieve better results, but the use of multiple PFC inductors will undoubtedly take up a lot of PCB board space, causing a tight layout on the board.

[0004] Therefore, it is necessary to propose a new technical solution to address the above problems. Utility Model Content

[0005] To overcome the shortcomings mentioned above, this utility model aims to provide a technical solution that can solve the aforementioned problems.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a novel PFC inductor structure, comprising an upper magnetic core and a lower magnetic core arranged opposite to each other, as well as a left wire frame and a right wire frame; Winding regions are formed on both sides of the opposite side of the upper and lower magnetic cores. Each of the two winding regions is provided with an upper core post and a lower core post extending from the upper and lower magnetic cores respectively, and a magnetic core air gap is provided between the upper core post and the lower core post. The left and right winding frames are respectively located in the two winding areas and sleeved on the outside of the upper and lower core columns. The left and right winding frames are respectively wound with a left coil and a right coil. A partition is provided on the lower core post, and a magnetic sheet is provided on the partition. The partition and the magnetic sheet are stacked in the air gap of the magnetic core.

[0007] As a further embodiment of this utility model: multiple partition plates and magnetic sheets are provided, and they are stacked alternately in the air gap of the magnetic core.

[0008] As a further embodiment of this utility model, the partition is made of epoxy resin board.

[0009] As a further embodiment of this utility model, the magnetic sheet is made of the same material as the upper magnetic core and the lower magnetic core.

[0010] As a further embodiment of this utility model: the upper magnetic core and the lower magnetic core respectively include an upper magnetic block and a lower magnetic block, and an upper partition block and a lower partition block are respectively provided on the opposite side of the upper magnetic block and the lower magnetic block, so that the two sides of the opposite side of the upper magnetic block and the lower magnetic block are divided into two winding areas by the upper partition block and the lower partition block.

[0011] As a further embodiment of this utility model: the left and right wire frames are respectively provided with a left cylinder and a right cylinder for winding the left coil and the right coil. The upper and lower sides of the left and right cylinders are respectively provided with two first side plates and two second side plates, and the lower first side plate and the lower second side plate are provided with pins.

[0012] As a further embodiment of this utility model: a first stop block and a second stop block are respectively provided on the opposite side of the first side plate and the second side plate, so that two limiting slots are formed between the two first side plates and the two second side plates, which respectively act on the upper magnetic block and the lower magnetic block.

[0013] As a further embodiment of this utility model: V-shaped openings are formed at both ends of the limiting groove, and the two ends of the upper magnetic block and the lower magnetic block are matched with the shape of the V-shaped openings.

[0014] Compared with the prior art, the beneficial effects of this technical solution are as follows: the left and right coils are respectively fitted outside the upper and lower core columns. After the left and right coils wound on them are energized, they work in the circuit. When the inductor is working, the magnetic flux generated by the left and right coils will pass through their corresponding magnetic core air gaps. At this time, due to the stacking of the partition and the magnetic sheet in the magnetic core air gap, the space of the magnetic core air gap is divided by the partition, thereby dispersing the magnetic flux and avoiding the magnetic flux from concentrating and crossing in the magnetic core air gap, avoiding the occurrence of severe local heating, and improving the long-term working stability of the inductor. By designing the upper and lower magnetic cores, two independent winding areas are formed between them, allowing the left and right lead frames to be set in the two winding areas respectively. This integrates the two windings into a set of upper and lower magnetic cores, thereby reducing the area occupied by the inductor on the PCB board and alleviating the problem of limited PCB board space.

[0015] Additional aspects and advantages of this invention 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 the invention. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a cross-sectional structural schematic diagram of the present invention; Figure 3 This is a schematic diagram of the upper and lower magnetic cores of this utility model; Figure 4 This is a structural schematic diagram of the left and right wire frames of this utility model; The corresponding labels in the attached diagram are explained as follows: 1. Upper magnetic core; 11. Upper core post; 12. Upper magnetic block; 13. Upper spacer; 2. Lower magnetic core; 21. Lower core post; 22. Lower magnetic block; 23. Lower spacer; 3. Left wire frame; 31. Left coil; 32. Left cylinder; 33. First side plate; 34. First stop block; 4. Right wire frame; 41. Right coil; 42. Right cylinder; 43. Second side plate; 44. Second stop block; 5. Winding area; 6. Magnetic core air gap; 7. Spacer; 8. Magnetic sheet; 9. Pin; 10. Limiting slot. Detailed Implementation

[0018] 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.

[0019] Please see Figure 1-4 A novel PFC inductor structure includes an upper magnetic core 1 and a lower magnetic core 2 arranged opposite to each other, as well as a left wire frame 3 and a right wire frame 4; Winding regions 5 are formed on both sides of the opposite side of the upper magnetic core 1 and the lower magnetic core 2. Each of the two winding regions 5 is provided with an upper core post 11 and a lower core post 21 extending from the upper magnetic core 1 and the lower magnetic core 2 respectively, and a magnetic core air gap 6 is provided between the upper core post 11 and the lower core post 21. Left wire frame 3 and right wire frame 4 are respectively set in the two winding areas 5 and sleeved outside the upper core column 11 and lower core column 21. Left coil 31 and right coil 41 are respectively wound on left wire frame 3 and right wire frame 4. A partition 7 is provided on the lower core column 21, and a magnetic sheet 8 is provided on the partition 7. The partition 7 and the magnetic sheet 8 are stacked in the air gap 6 of the magnetic core.

[0020] Specifically, the left coil 3 and the right coil 4 are respectively fitted around the upper core post 11 and the lower core post 21. The left coil 31 and the right coil 41 wound on them work in the circuit after being energized. When the inductor is working, the magnetic flux generated by the left coil 31 and the right coil 41 will pass through their respective magnetic core air gaps 6. At this time, due to the stacking of the partition 7 and the magnetic sheet 8 in the magnetic core air gap 6, the space of the magnetic core air gap 6 is divided by the partition 7, thereby dispersing the magnetic flux and preventing the magnetic flux from concentrating and crossing in the magnetic core air gap 6, avoiding local severe heating, and improving the long-term working stability of the inductor. By designing the upper magnetic core 1 and the lower magnetic core 2, two independent winding areas 5 are formed between the upper magnetic core 1 and the lower magnetic core 2, allowing the left wire frame 3 and the right wire frame 4 to be set in the two winding areas 5 respectively, so that the two windings are integrated into a set of upper magnetic core 1 and lower magnetic core 2, thereby reducing the area occupied by the inductor on the PCB board and alleviating the problem of PCB board space constraints.

[0021] Based on the above embodiments, it is further proposed that multiple partition plates 7 and magnetic sheets 8 are provided and are alternately stacked in the air gap 6 of the magnetic core.

[0022] Specifically, multiple partitions 7 and magnetic sheets 8 can be provided, which can divide the magnetic core air gap 6 into multiple small air gaps. Furthermore, by flexibly adjusting the number and thickness of partitions 7 and magnetic sheets 8, circuits with different power requirements can be adapted.

[0023] Preferably, the partition 7 is made of epoxy resin board.

[0024] Preferably, the magnetic sheet 8 is made of the same material as the upper magnetic core 1 and the lower magnetic core 2.

[0025] Furthermore, the upper magnetic core 1 and the lower magnetic core 2 respectively include an upper magnetic block 12 and a lower magnetic block 22. An upper partition block 13 and a lower partition block 23 are respectively provided on the opposite side of the upper magnetic block 12 and the lower magnetic block 22. The upper partition block 13 and the lower partition block 23 divide the two sides of the opposite side of the upper magnetic block 12 and the lower magnetic block 22 into two winding regions 5.

[0026] Specifically, after assembling the upper magnetic core 1 and the lower magnetic core 2, the upper spacer 13 and the lower spacer 23 come into contact with each other, forming a partition between the upper magnetic block 12 and the lower magnetic block 22, thereby separating two winding regions 5.

[0027] Based on the above embodiments, it is further proposed that the left wire frame 3 and the right wire frame 4 are respectively provided with a left cylinder 32 and a right cylinder 42 for winding the left coil 31 and the right coil 41. The upper and lower sides of the left cylinder 32 and the right cylinder 42 are respectively provided with two first side plates 33 and two second side plates 43, and the lower first side plate 33 and the lower second side plate 43 are both provided with pins 9.

[0028] Specifically, taking the left coil frame 3 as an example, the two first side plates 33 on the upper and lower sides of the left cylinder 32 respectively abut against the upper magnetic block 12 and the lower magnetic block 22, so that the left coil frame 3 is stable within the winding area 5. The lower first side plate 33 is provided with a PIN 9 so that the left coil 31 wound on the left cylinder 32 can be led out and connected to the PIN 9 for winding and soldering. When the inductor is installed on the PCB board, it is connected and soldered to the corresponding hole on the PCB board through the PIN 9, so that the left coil 31 is connected to the circuit. Preferably, the first side plate 33 is also provided with a wire hole (not shown in the figure) to facilitate the accurate lead-out of the connecting wire of the left coil 31. The structure of the right wire frame 4 is similar to that of the left wire frame 3, so we will not go into too much detail here.

[0029] Preferably, a first stop 34 and a second stop 44 are respectively provided on the opposite side of the first side plate 33 and the second side plate 43, so that two limiting slots 10 are formed between the two first side plates 33 and the two second side plates 43, which respectively act on the upper magnetic block 12 and the lower magnetic block 22.

[0030] Specifically, a first stop 34 and a second stop 44 are respectively provided on opposite sides of the first side plate 33 and the second side plate 43, so that a limiting slot 10 is formed between the first side plate 33 and the second side plate 43. When the left wire frame 3 and the right wire frame 4 are assembled between the upper magnetic core 1 and the lower magnetic core 2, the limiting slot 10 can be used to limit the upper magnetic core 1 and the lower magnetic core 2. Combined with the bonding of epoxy resin, the overall structure of the inductor is stabilized.

[0031] Preferably, the limiting slot 10 has V-shaped openings at both ends, and the ends of the upper magnetic block 12 and the lower magnetic block 22 match the shape of the V-shaped openings. The formation of the V-shaped openings and the corresponding shape design of the ends of the upper magnetic block 12 and the lower magnetic block 22 can enhance the limiting effect of the limiting slot 10 on the upper magnetic core 1 and the lower magnetic core 2, and prevent the upper magnetic core 1 and the lower magnetic core 2 from moving forward, backward, left, or right.

[0032] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A novel PFC inductor structure, characterized in that, Includes an upper magnetic core (1) and a lower magnetic core (2) arranged opposite to each other, as well as a left wire frame (3) and a right wire frame (4); Winding regions (5) are formed on both sides of the opposite side of the upper magnetic core (1) and the lower magnetic core (2). Each of the two winding regions (5) is provided with an upper core post (11) and a lower core post (21) extending from the upper magnetic core (1) and the lower magnetic core (2), respectively. A magnetic core air gap (6) is provided between the upper core post (11) and the lower core post (21). The left wire frame (3) and the right wire frame (4) are respectively set in the two winding areas (5) and sleeved on the outside of the upper core column (11) and the lower core column (21). The left wire frame (3) and the right wire frame (4) are respectively wound with a left coil (31) and a right coil (41). A partition (7) is provided on the lower core column (21), and a magnetic sheet (8) is provided on the partition (7), and the partition (7) and the magnetic sheet (8) are stacked in the air gap (6) of the magnetic core.

2. The novel PFC inductor structure according to claim 1, characterized in that, Multiple partitions (7) and magnetic sheets (8) are provided and are stacked alternately in the air gap (6) of the magnetic core.

3. The novel PFC inductor structure according to claim 2, characterized in that, The partition (7) is made of epoxy resin board.

4. The novel PFC inductor structure according to claim 3, characterized in that, The magnetic sheet (8) is made of the same material as the upper magnetic core (1) and the lower magnetic core (2).

5. The novel PFC inductor structure according to claim 1, characterized in that, The upper magnetic core (1) and the lower magnetic core (2) respectively include an upper magnetic block (12) and a lower magnetic block (22). An upper partition (13) and a lower partition (23) are respectively provided on the opposite side of the upper magnetic block (12) and the lower magnetic block (22). The upper partition (13) and the lower partition (23) divide the two sides of the opposite side of the upper magnetic block (12) and the lower magnetic block (22) into two winding areas (5).

6. The novel PFC inductor structure according to claim 5, characterized in that, The left wire frame (3) and the right wire frame (4) are respectively provided with a left cylinder (32) and a right cylinder (42) for winding the left coil (31) and the right coil (41). The left cylinder (32) and the right cylinder (42) are respectively provided with two first side plates (33) and two second side plates (43) on the upper and lower sides, and PIN feet (9) are provided on the lower first side plate (33) and the lower second side plate (43).

7. The novel PFC inductor structure according to claim 6, characterized in that, The first side plate (33) and the second side plate (43) are respectively provided with a first stop (34) and a second stop (44), so that two limiting slots (10) are formed between the two first side plates (33) and the two second side plates (43) respectively, which act on the upper magnetic block (12) and the lower magnetic block (22).

8. The novel PFC inductor structure according to claim 7, characterized in that, The limiting slot (10) has V-shaped openings at both ends, and the two ends of the upper magnetic block (12) and the lower magnetic block (22) match the shape of the V-shaped openings.

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