Cylindrical hybrid material inductor and cylindrical two-path magnetic integrated inductor
Patent Information
- Application Number
- CN202522276190.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-28
- Publication Date
- 2026-09-29
- Estimated Expiration
- 2035-10-28
AI Technical Summary
同时，虽然环形电感以其低成本、高可靠性在此行业得到大规模应用，但环形电感无法自动化绕线导致的产能受限、外形一致性差对相关产业的限制越来越严重
[0005]本新型的有益效果是：采用双层立绕扁铝线绕组或双层立绕扁铜包铝线绕组，不仅使绕组高度在匝数较多时不至于太高，而且在涡流损耗、散热能力以及生产效率之间都得到很好的权衡，并且双层绕组结构使出线头位于同侧，方便做磁集成的结构设计。同时，采用两种或两种以上的磁芯材料组成混合磁芯，可以根据不同的应用场景最大限度的利用每种材料的价格和性能优势，形成最优解决方案。本新型电感的每个零组件都可以独立预制，可以通过自动化组装完成整个产品的生产，生产效率高。
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Figure CN224816953U_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a cylindrical hybrid material inductor, and more particularly to a cylindrical hybrid material inductor made using hybrid materials. Background Technology
[0002] With the large-scale development and application of photovoltaic and energy storage industries, related component industries have also experienced significant growth. Magnetic components, as major components with a high proportion of raw material costs, face an increasingly urgent need for cost reduction and efficiency improvement. Furthermore, while copper wire has been used as an excellent conductor in this field for many years, the gradual depletion and uneven distribution of copper resources are increasingly constraining related industries. At the same time, although toroidal inductors are widely used in this industry due to their low cost and high reliability, the inability to automate winding leads to limited production capacity and poor shape consistency, further restricting related industries. Utility Model Content
[0003] To provide a product that can be automated, has lower cost, higher efficiency, and enables pin-to-pin replacement without changing the shape of the mounting housing, this invention provides a cylindrical hybrid material inductor. The technical solution of this invention is as follows: a cylindrical central magnetic core and a double-layer vertically wound flat aluminum wire winding or a double-layer vertically wound flat copper-clad aluminum wire winding are provided at both ends of the cylindrical magnetic core. The thickness of the plate-shaped yoke magnetic core is less than or equal to 0.35 times the diameter of the cylindrical magnetic core. The plate-shaped yoke magnetic core has through holes or notches for wire exit, potting, and heat dissipation. An outer ring magnetic core is provided, which, together with the cylindrical magnetic core and the plate-shaped yoke cores at both ends, forms a closed magnetic circuit. The inner diameter of the ring magnetic core is greater than or equal to 1.6 times the diameter of the cylindrical magnetic core.
[0004] This invention also provides a cylindrical two-way magnetic integrated inductor, the technical solution of which is as follows: two cylindrical central cores connected in series and a double-layer vertically wound flat aluminum wire winding or a double-layer vertically wound flat copper-clad aluminum wire winding; each end of the two cylindrical central cores and the series end are provided with a plate-type yoke core, the thickness of the plate-type yoke core is less than or equal to 0.35 times the diameter of the cylindrical central core, and the plate-type yoke core has through holes or notches for wire exit, potting and glue injection, and air blowing for heat dissipation; correspondingly, there is a ring-shaped magnetic core on the outer side, which, together with the cylindrical central core and the plate-type yoke cores at both ends, forms a closed magnetic circuit; the inner diameter of the ring-shaped magnetic core is greater than or equal to 1.6 times the diameter of the cylindrical central core.
[0005] The advantages of this new type of inductor are as follows: The use of double-layer vertically wound flat aluminum wire windings or double-layer vertically wound flat copper-clad aluminum wire windings not only prevents the winding height from becoming excessive when the number of turns is high, but also achieves a good balance between eddy current loss, heat dissipation capacity, and production efficiency. Furthermore, the double-layer winding structure ensures that the lead ends are located on the same side, facilitating the design of magnetically integrated structures. Simultaneously, the use of two or more core materials to form a hybrid core allows for the maximum utilization of the price and performance advantages of each material to create an optimal solution for different application scenarios. Each component of this new type of inductor can be prefabricated independently, and the entire product can be manufactured through automated assembly, resulting in high production efficiency. Attached Figure Description
[0006] Figure 1 This is a simplified schematic diagram of the magnetic circuit structure of the iron core;
[0007] Figure 2 This is an exploded view of the structure of this novel invention;
[0008] Figure 3 An exploded view of the structure with the two yokes misaligned by 90°.
[0009] Figure 4 This is an exploded view of the structure of two plate-type yoke magnetic cores with different diameters in this novel design.
[0010] Figure 5 This is an exploded view of the structure of the novel cylindrical dual-path magnetic integrated inductor.
[0011] In the diagram, 1: cylindrical center core; 2: double-layer vertically wound flat aluminum wire winding or double-layer vertically wound flat copper-clad aluminum wire winding; 3: plate yoke core; 31: through hole; 32: blind hole; 4: toroidal core; 5: wire end; D3-1: large diameter (plate yoke core); D3-2: small diameter (plate yoke core); D4: inner diameter (toroidal core). Detailed Implementation
[0012] This invention provides a cylindrical hybrid material inductor constructed using double-layer vertically wound flat aluminum wire or double-layer vertically wound flat copper-clad aluminum wire as the conductor material and a hybrid magnetic circuit composed of various magnetic cores. While aluminum, as a good conductor of electricity, is slightly inferior to copper in conductivity, it is far superior in terms of cost, production volume, and mineral reserves. Therefore, using large-section aluminum wire or copper-clad aluminum wire can balance cost reduction and efficiency improvement. Since the resistivity of aluminum wire is slightly greater than that of copper wire, the cross-sectional area of the aluminum wire or copper-clad aluminum wire needs to be larger than that of the copper wire. The hardness and ductility of metallic aluminum determine that the minimum thickness of the flat aluminum wire currently used in vertical winding processes is approximately 1 mm. Therefore, when increasing the amount of aluminum wire to improve efficiency and reduce overall cost, double-layer vertically wound flat aluminum wire windings or double-layer vertically wound flat copper-clad aluminum wire windings are required. Using double-layer vertically wound windings not only prevents the winding height from becoming too high when the number of turns is large, but also achieves a good balance between eddy current losses, heat dissipation capacity, and manufacturing processes. Because the unit volume cost of aluminum is lower than that of iron core material, the more aluminum used, the lower the overall cost of the inductor, provided the inductor performance requirements are met. This necessitates a smaller cylindrical core cross-section and a larger winding window area. However, considering the inductor's shape and manufacturing limitations, a ratio between the cross-sectional area of the cylindrical core and the winding window area between the toroidal core and the cylindrical core is typically found to balance cost and efficiency when the inner diameter of the toroidal core is greater than or equal to 1.6 times the diameter of the cylindrical core. Furthermore, this novel design employs a hybrid core composed of two or more core materials, maximizing the price and performance advantages of each material to create an optimal solution for different application scenarios.
[0013] When different core materials are used for the cylindrical center core and the plate yoke core of a cylindrical hybrid material inductor, the continuity of magnetic flux must be maintained at the interface between the two cores. Therefore, the product of the maximum magnetic flux density of the cylindrical center core and its cross-sectional area must equal the product of the maximum magnetic flux density of the plate yoke core and its cross-sectional area. Typically, to reduce DC resistance, a smaller cross-sectional area is required for the cylindrical center core; therefore, a core material with high saturation magnetic flux density is used to meet the inductor's energy storage requirements. The plate yoke core, located outside the coil, is less constrained by the coil's dimensions and can have a larger cross-sectional area. While maintaining magnetic flux continuity, it can also provide some magnetic shielding; therefore, a material with high permeability and low magnetic flux density can be used. Figure 1 As shown, the cylindrical central core has a diameter D and a maximum magnetic flux density Bc = 1.2T. The plate-type yoke core has a thickness ht and a maximum magnetic flux density Be = 0.75T. The continuity requirement for the magnetic flux is 0.25 * D. 2From *π*Bc=D*π*ht*Be, we can obtain ht=0.4D. Considering the influence of magnetic flux diffusion, simulation shows that approximately 15% of the magnetic flux on the cylindrical core diffuses to the winding window, and the actual magnetic flux passing through the plate yoke core is only about 85% of that on the cylindrical core. Therefore, ht≈0.4D*85%=0.34D. Taking into account the performance errors of different cores, the thickness of the plate yoke core is generally less than or equal to 0.35 times the diameter of the cylindrical core.
[0014] Based on the above solutions and research data, such as Figure 2 , 3 The structure of this novel structure is as follows: A cylindrical central magnetic core 1 is wound with a double-layer vertically wound flat aluminum wire winding or a double-layer vertically wound flat copper-clad aluminum wire winding 2. At each end of the cylindrical central magnetic core 1 is a plate-type yoke magnetic core 3. The thickness of the plate-type yoke magnetic core 3 is less than or equal to 0.35 times the diameter of the cylindrical central magnetic core 1. The plate-type yoke magnetic core 3 has through holes 31 or notches for wire exit, potting, and heat dissipation. An annular magnetic core 4 is located on the outer side, forming a closed magnetic circuit with the cylindrical central magnetic core 1 and its two end plate-type yoke magnetic cores 3. The inner diameter of the annular magnetic core 4 is greater than or equal to 1.6 times the diameter of the cylindrical central magnetic core 1. As an optimization, this novel structure can adopt any of the following improvements:
[0015] The cylindrical central magnetic core 1 is composed of one or more segments, with air gaps between the segments.
[0016] The plate-type yoke core 3 is made of magnetic powder core material, including but not limited to iron-silicon, iron-silicon-aluminum, etc.
[0017] like Figure 3 As shown, the plate-type yoke ferromagnetic core 3 has blind holes 32 for positioning the cylindrical central core 1. The through holes 31 or notches on the two plate-type yoke ferromagnetic cores 3 are staggered, preferably at a staggered angle of 90 degrees.
[0018] The outer ring core 4 is made of ferrite, amorphous, nanocrystalline, or iron-silicon-aluminum material; the outer ring core 4 is composed of one or more segments;
[0019] The product of the permeability and cross-sectional area of the outer annular magnetic core 4 is greater than twice the product of the permeability and cross-sectional area of the cylindrical inner core 1, so as to achieve better magnetic shielding performance and reduce coupling and interference between inductors.
[0020] When assembling the inductor, first, place a pre-made double-layer vertically wound flat aluminum wire winding or double-layer vertically wound flat copper-clad aluminum wire winding 2 onto the cylindrical central core 1. Then, apply glue to the plate-side yoke core 3 and assemble it at both ends of the cylindrical central core 1. Finally, apply glue to the toroidal core 4 and bake. When the cylindrical central core 1 consists of two sections, the two plate-side yoke cores 3 and the two sections of the cylindrical central core 1 can be glued together to form two T-shaped cores. Then, place the pre-made double-layer vertically wound flat aluminum wire winding or double-layer vertically wound flat copper-clad aluminum wire winding 2 and the toroidal core 4 on top and bake.
[0021] like Figure 4 As shown, preferably, the two plate-type yoke cores 3 have different diameters, which are larger and smaller than the inner diameter D4 of the toroidal core 4, respectively. When assembling the inductor, first, the cylindrical center core 1 and the large-diameter D3-1 plate-type yoke core 3 are bonded together. Then, a pre-fabricated double-layer vertically wound flat aluminum wire winding or double-layer vertically wound flat copper-clad aluminum wire winding 2 is fitted on. After bonding the small-diameter D3-2 plate-type yoke core 3, the toroidal core 4 is fitted on from top to bottom, followed by adhesive application and baking. Blind holes 32 are provided on the plate-type yoke core 3 to facilitate the positioning of the cylindrical center core 1.
[0022] As shown in the figure Figure 5 As shown, this invention also provides a cylindrical dual-path magnetic integrated inductor, comprising two series-connected cylindrical central cores 1 and a double-layer vertically wound flat aluminum wire winding or a double-layer vertically wound flat copper-clad aluminum wire winding 2; each end of the two cylindrical central cores 1 and each series end is provided with a plate-type yoke core 3, the thickness of which is less than or equal to 0.35 times the diameter of the cylindrical central core 1, and the plate-type yoke core 3 has through holes 31 or notches for wire exit, potting, and heat dissipation; correspondingly, an annular core 4 is provided on the outer side, forming a closed magnetic circuit with the cylindrical central core 1 and the plate-type yoke cores 3 at both ends, the inner diameter of which is greater than or equal to 1.6 times the diameter of the cylindrical central core 1. Figure 4 In the structure shown, as a limitation, the diameter of the plate-type yoke core 3 at the series end is a large diameter D3-1, which is larger than the inner diameter D4 of the toroidal core 4. The diameter of the plate-type yoke cores 3 at both ends is a small diameter D3-2, which is smaller than the inner diameter D4 of the toroidal core 4. In this structure, the two inductors are placed back-to-back and share a large diameter D3-1 plate-type yoke core 3. This design can further reduce cost and size.
[0023] The specific embodiments described above are merely exemplary and are intended to enable those skilled in the art to better understand this patent. They should not be construed as limiting the scope of this patent. Any changes or modifications to the technical content that are substantially the same or equivalent to the technical solutions disclosed in this patent shall fall within the scope of this patent.
Claims
1. A cylindrical hybrid material inductor, characterized in that: There is a cylindrical central core (1) and a double-layer vertical flat aluminum wire winding or a double-layer vertical flat copper-clad aluminum wire winding (2); a plate yoke iron core (3) is provided at each end of the cylindrical central core (1), the thickness of the plate yoke iron core (3) is less than or equal to 0.35 times the diameter of the cylindrical central core (1), and the plate yoke iron core (3) has a through hole (31) or a notch, which is used for wire end (5) to exit, potting glue and blowing heat; there is an annular core (4) on the outside, which forms a closed magnetic circuit with the cylindrical central core (1) and the plate yoke iron cores (3) at both ends, and the inner diameter of the annular core (4) is greater than or equal to 1.6 times the diameter of the cylindrical central core (1).
2. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The cylindrical central core (1) and the plate yoke core (3) are made of magnetic powder core material.
3. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The cylindrical central core (1) is composed of one or more segments, with air gaps between the segments.
4. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The plate-shaped yoke ferromagnetic core (3) has blind holes (32) for positioning the cylindrical central core (1).
5. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The through holes (31) or notches on the two plate-shaped yoke ferromagnetic cores (3) are misaligned.
6. The cylindrical hybrid material inductor as described in claim 5, characterized in that: The misalignment angle of the through hole (31) or notch is 90 degrees.
7. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The toroidal magnetic core (4) is composed of one or more segments.
8. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The product of the permeability and cross-sectional area of the toroidal core (4) is greater than twice the product of the permeability and cross-sectional area of the cylindrical core (1).
9. The cylindrical hybrid material inductor as described in claim 1, characterized in that: The diameters of the plate yoke cores (3) are different, with the smaller diameter (D3-2) being smaller than the inner diameter (D4) of the toroidal core (4), and the larger diameter (D3-1) being larger than the inner diameter (D4) of the toroidal core (4).
10. A cylindrical dual-path magnetic integrated inductor, characterized in that: There are two cylindrical central cores (1) connected in series and two double-layer vertical flat aluminum wire windings or double-layer vertical flat copper-clad aluminum wire windings (2); each of the two cylindrical central cores (1) is provided with a plate yoke iron core (3) at both ends and at the series end. The thickness of the plate yoke iron core (3) is less than or equal to 0.35 times the diameter of the cylindrical central core (1). The plate yoke iron core (3) has through holes (31) or notches. The through holes (31) or notches are used for wire exit (5), potting and heat dissipation. Correspondingly, there is an annular core (4) on the outer side, which, together with the cylindrical central core (1) and the plate yoke iron cores (3) at both ends, forms a closed magnetic circuit. The inner diameter of the annular core (4) is greater than or equal to 1.6 times the diameter of the cylindrical central core (1).
11. The cylindrical dual-path magnetic integrated inductor as described in claim 10, characterized in that: The diameter of the plate yoke core (3) at the series end is a large diameter (D3-1), which is larger than the inner diameter (D4) of the toroidal core (4). The diameter of the plate yoke core (3) at both ends is a small diameter (D3-2), which is smaller than the inner diameter (D4) of the toroidal core (4).