A low-loss high-efficiency resonant inductance structure

Abstract

The utility model discloses a kind of low-loss high-efficiency resonant inductance structure, it is related to inductance technical field, including magnetic core, coil position is formed in magnetic core interior, coil is arranged in coil position, magnetic core interior is also provided with upper core column and lower core column, magnetic core air gap is equipped between upper core column and lower core column, coil is wound in upper core column and lower core column outside, upper core column and lower core column outside are provided with isolator, magnetic core air gap is isolated with coil by isolator;Isolator is arranged between coil and magnetic core air gap, and the magnetic field guidance and eddy current shielding double effect of isolator, the coupling path of magnetic core air gap diffusion magnetic field and coil is blocked, reduce the ACR loss of coil from the root;Meanwhile, isolator does not change the magnetic flux distribution of magnetic core main magnetic circuit, guarantee the stability of inductance value, quality factor, finally satisfy the demand of high-frequency, high-power electronic system to low-loss, miniaturization inductance, it can be widely applied in switching power supply, new energy converter, high-frequency communication equipment and other fields.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and in particular to a low-loss, high-efficiency resonant inductor structure. Background Technology

[0002] Resonant inductors, as key components of high-frequency power electronic systems, mainly consist of a magnetic core assembly and a coil. Their basic working principle involves generating a magnetic field by energizing the coil, utilizing the magnetic permeability of the core to achieve energy storage and conversion. To avoid core saturation, an air gap is typically placed at the core's joints. Structurally, existing resonant inductor coils are mostly wound directly on the core's central column, resulting in a relatively close distance between the coil and the air gap. To reduce alternating current resistance (ACR), current technologies primarily employ the following optimization methods: (1). Coil material: Multi-strand enameled wire (Litz wire) is used instead of single-strand wire to alleviate skin effect.

[0003] (2). Winding process: reduce the proximity effect between coils by sparse winding and layered winding.

[0004] (3) Core processing: Use multi-segment air gaps instead of single air gaps.

[0005] The above structure is widely used in switching power supplies, new energy converters and other scenarios, but there is still room for improvement in optimizing its ACR value when operating at high frequencies.

[0006] Existing resonant inductor technology has the following core drawbacks in high-frequency operating scenarios: (1). The edge effect of the air gap in the magnetic core causes a surge in eddy current losses in the coil: In existing technologies, the presence of an air gap in the magnetic core can cause a "edge effect" in the magnetic field—the magnetic field lines at the air gap deviate from the regular path of the magnetic core and diffuse into the surrounding space, forming a leakage magnetic field. When this leakage magnetic field passes through a nearby coil conductor, it induces additional eddy currents, increasing the coil's equivalent alternating resistance (ACR).

[0007] (2). Near-field coupling between the coil and the magnetic core exacerbates current distribution distortion: In the existing structure, the distance between the coil and the air gap of the magnetic core is too close. The high-frequency strong magnetic field at the air gap forms a tight coupling with the coil, causing the current in the conductor to concentrate on the side close to the air gap (the skin effect and the proximity effect are superimposed). The equivalent conductive cross-sectional area is reduced, which further increases the ACR value. Even if multiple strands of Litz wire are used, it can only alleviate part of the skin effect and cannot block the root cause of magnetic field coupling.

[0008] Therefore, it is necessary to propose a new technical solution to address the above problems. Utility Model Content

[0009] To overcome the shortcomings mentioned above, this utility model aims to provide a technical solution that can solve the aforementioned problems.

[0010] To achieve the above objectives, this utility model provides the following technical solution: a low-loss, high-efficiency resonant inductor structure, comprising a magnetic core, a coil position formed inside the magnetic core, a coil disposed in the coil position, an upper core post and a lower core post disposed inside the magnetic core, a magnetic core air gap disposed between the upper core post and the lower core post, the coil being wound around the upper core post and the lower core post, and an isolation member disposed outside the upper core post and the lower core post, the isolation member isolating the magnetic core air gap from the coil.

[0011] As a further embodiment of this utility model: the isolation element is an isolation ring, which has a hollow structure that covers the outside of the upper core post and the lower core post and covers the air gap of the magnetic core.

[0012] As a further embodiment of this invention, the isolation ring is made of engineering plastic.

[0013] As a further embodiment of this utility model: the two sides of the isolation ring abut against the top and bottom walls of the coil position.

[0014] As a further embodiment of this utility model: the magnetic core includes an upper core seat and a lower core seat arranged opposite to each other, and the upper core post and the lower core post are respectively connected to the upper core seat and the lower core seat; Upper core block and lower core block are respectively provided on both sides of the upper core seat and the lower core seat. The upper core block and the lower core block are connected to each other to form a coil position between the upper core seat and the lower core seat.

[0015] As a further embodiment of this utility model: a heat sink is provided on the upper core seat, and heat-conducting pillars are provided on both sides of the upper core seat. The heat-conducting pillars are connected to the heat sink, and the heat-conducting pillars extend to the coil position and fit against the isolation ring.

[0016] As a further embodiment of this utility model: the upper core seat has slots on both sides that communicate with the coil position, and the heat-conducting column is fitted into the slots.

[0017] As a further embodiment of this utility model: a connecting plate that fits against the upper surface of the upper core seat is connected between the two heat-conducting pillars, and a limiting groove is opened on the lower end face of the heat sink, and the connecting plate is fitted into the limiting groove.

[0018] As a further embodiment of this utility model: a positioning hole is provided on the connecting plate, and a positioning post is provided in the limiting groove, with the positioning post interlocking with the positioning hole.

[0019] As a further embodiment of this utility model: the heat sink is made of aluminum. The heat-conducting column is made of ceramic material.

[0020] Compared with existing technologies, the beneficial effects of this technical solution are as follows: Addressing the problem of excessively high AC resistance (ACR) values ​​in resonant inductors due to the edge effect of the magnetic core air gap and near-field coupling between the coil and the magnetic core air gap, this invention sets up an isolation component between the coil and the magnetic core air gap. Through the dual effects of magnetic field guidance and eddy current shielding of the isolation component, the coupling path between the diffused magnetic field of the magnetic core air gap and the coil is blocked, fundamentally reducing the ACR loss of the coil. Simultaneously, the isolation component does not change the magnetic flux distribution of the main magnetic circuit of the magnetic core, ensuring the stability of the inductance value (L) and quality factor (Q). Ultimately, it meets the requirements of high-frequency, high-power electronic systems for low-loss, miniaturized inductors, while also balancing performance and cost. It can be widely used in switching power supplies, new energy converters, high-frequency communication equipment, and other fields.

[0021] 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

[0022] 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.

[0023] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a cross-sectional structural diagram of the present invention; Figure 3 This is a partial structural schematic diagram of the present invention; Figure 4 This is a schematic diagram of the magnetic core of this utility model; Figure 5 This is a schematic diagram of the structure of the heat sink of this utility model; Figure 6 This is a schematic diagram of the structure of the heat-conducting column of this utility model; The corresponding labels in the attached diagram are explained as follows: 1. Magnetic core; 11. Upper core post; 12. Lower core post; 13. Upper core seat; 131. Slot; 14. Lower core seat; 15. Upper core block; 16. Lower core block; 2. Coil position; 3. Coil; 4. Magnetic core air gap; 5. Isolator; 51. Isolation ring; 6. Heat sink; 61. Limiting groove; 62. Positioning post; 7. Heat-conducting post; 71. Connecting plate; 72. Positioning hole. Detailed Implementation

[0024] 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.

[0025] Please see Figure 1-6 A low-loss, high-efficiency resonant inductor structure includes a magnetic core 1, a coil position 2 formed inside the magnetic core 1, a coil 3 disposed in the coil position 2, an upper core post 11 and a lower core post 12 disposed inside the magnetic core 1, a magnetic core air gap 4 disposed between the upper core post 11 and the lower core post 12, the coil 3 being wound around the outside of the upper core post 11 and the lower core post 12, and an isolator 5 disposed outside the upper core post 11 and the lower core post 12, the isolator 5 isolating the magnetic core air gap 4 from the coil 3.

[0026] Specifically, addressing the problem of excessively high AC resistance (ACR) values ​​in resonant inductors due to edge effects in the air gap 4 of the magnetic core and near-field coupling between the coil 3 and the air gap 4, this invention incorporates an isolation component 5 between the coil 3 and the air gap 4. Through the dual effects of magnetic field guidance and eddy current shielding of the isolation component 5, the coupling path between the diffused magnetic field of the air gap 4 and the coil 3 is blocked, thereby reducing the ACR loss of the coil 3 at its source. Simultaneously, the isolation component 5 does not alter the flux distribution of the main magnetic circuit of the magnetic core 1, ensuring the stability of the inductance value (L) and quality factor (Q). Ultimately, this meets the requirements of high-frequency, high-power electronic systems for low-loss, miniaturized inductors, while also balancing performance and cost. It can be widely applied in fields such as switching power supplies, new energy converters, and high-frequency communication equipment.

[0027] Based on the above embodiments, it is further proposed that the isolation element 5 is an isolation ring 51, which has a hollow structure that covers the outside of the upper core post 11 and the lower core post 12 and covers the magnetic core air gap 4.

[0028] Specifically, the isolation ring 51 is made according to the shape and structure of the upper core post 11 and the lower core post 12, forming an effective isolation between the magnetic core air gap 4 and the coil 3, cutting off the generation and conduction of eddy currents from the physical path, and ultimately achieving the purpose of reducing eddy current loss and optimizing ACR.

[0029] Preferably, the isolation ring 51 is made of engineering plastic.

[0030] Specifically, the isolation ring 51 can be made of materials such as PET T10G30, which incorporates 30% glass fiber (GF30) to give it high insulation, thermal stability, and high strength. The high insulation resistance can block the electrical coupling between the coil 3 and the air gap 4 of the magnetic core, avoiding parasitic losses. After being reinforced with glass fiber, the isolation ring 51 can maintain structural stability at high temperatures, adapting to the thermal environment during inductor operation and preventing isolation failure due to material deformation. At the same time, sufficient mechanical strength can support a thinner and lighter structural design, and also avoids damage and deformation during assembly and long-term use.

[0031] Preferably, the two sides of the isolation ring 51 abut against the top and bottom walls of the coil position 2.

[0032] Specifically, the isolation ring 51 abuts against the inner wall of the coil position 2 on both sides. Combined with the isolation ring 51 being sleeved on the outside of the upper core post 11 and the lower core post 12, the position of the isolation ring 51 is stable, which can prevent axial movement or lateral displacement under vibration or impact environment, and ensure that the isolation ring 51 is always in the designed position, maintaining the isolation effect between the magnetic core air gap 4 and the coil 3.

[0033] Preferably, the coil position 2 has openings on both sides that communicate with the outside.

[0034] Specifically, when the inductor is working, the openings on both sides of coil position 2 form a current channel, which also exposes coil 3 to the external environment, thereby effectively improving the efficiency of heat dissipation inside the inductor and enhancing its heat dissipation performance.

[0035] Furthermore, the magnetic core 1 includes an upper core seat 13 and a lower core seat 14 disposed opposite to each other, and an upper core post 11 and a lower core post 12 are respectively connected to the upper core seat 13 and the lower core seat 14. Upper core block 15 and lower core block 16 are respectively provided on both sides of the upper core seat 13 and the lower core seat 14. The upper core block 15 and the lower core block 16 are connected to each other to form a coil position 2 between the upper core seat 13 and the lower core seat 14.

[0036] Specifically, such as Figure 4 As shown, when the upper core seat 13 and the lower core seat 14 are assembled together, the upper core block 15 and the lower core block 16 are attached to each other and fixed by means such as adhesive bonding, so that a coil position 2 for accommodating the coil 3 is formed between the upper core seat 13 and the lower core seat 14. At the same time, a magnetic core air gap 4 is formed between the upper core column 11 and the lower core column 12.

[0037] Based on the above embodiments, it is further proposed that a heat sink 6 is provided on the upper core seat 13, and heat conduction pillars 7 are provided on both sides of the upper core seat 13. The heat conduction pillars 7 are connected to the heat sink 6, and the heat conduction pillars 7 extend to the coil position 2 and are attached to the isolation ring 51.

[0038] Specifically, because the isolation ring 51 blocks the air gap 4 of the magnetic core and the coil 3, and is located inside the magnetic core 1 and surrounded by the external coil 3, the heat inside it is easy to accumulate and difficult to dissipate. At this time, by setting the heat-conducting column 7 as a thermal bridge to directly contact the isolation ring 51, the heat is conducted to the heat sink 6 on the upper core seat 13. The heat sink 6 increases the contact area with the air, and finally dissipates the heat, which can solve the problem of the isolation ring 51 being too hot, avoid local overheating, and improve the overall performance stability of the inductor.

[0039] Preferably, the upper core seat 13 has slots 131 on both sides that communicate with the coil position 2, and the heat-conducting column 7 is fitted into the slots 131 to ensure that the position of the heat-conducting column 7 is accurate and fixed.

[0040] Preferably, a connecting plate 71 is connected between the two heat-conducting pillars 7 and adheres to the upper surface of the upper core seat 13. A limiting groove 61 is opened on the lower end face of the heat sink 6, and the connecting plate 71 is fitted into the limiting groove 61. During the assembly process, the heat-conducting pillar 7 is first aligned with the slot 131 and inserted into the coil position 2 to adhere to the isolation ring 51. At this time, the connecting plate 71 between the two heat-conducting pillars 7 adheres to the upper surface of the upper core seat 13. Then, the heat sink 6 is placed on the surface of the upper core seat 13 and fixed with thermally conductive adhesive. At the same time, the limiting groove 61 and the connecting plate 71 are fitted together, so that the connecting plate 71 is pressed and fixed to the upper core seat 13 by the heat sink 6.

[0041] Preferably, the connecting plate 71 is provided with a positioning hole 72, and a positioning post 62 is provided in the limiting groove 61. The positioning post 62 and the positioning hole 72 are interlocked. While the heat sink 6 is pressing the connecting plate 71, the positioning post 62 on the limiting groove 61 and the positioning hole 72 on the connecting plate 71 are interlocked, thereby further fixing the connecting plate 71 and ensuring that the positions of the connecting plate 71 and the heat-conducting post 7 remain fixed.

[0042] Preferably, the heat sink 6 is made of aluminum, which is an excellent heat conductor and can quickly reduce the heat transferred by the heat conduction column 7 and disperse it throughout the entire body, ultimately dissipating the heat outward. The heat-conducting pillar 7 is made of ceramic material. The thermally conductive ceramic has insulation properties, which avoids contact with the coil 3 and thus avoids affecting the performance of the inductor. At the same time, it can efficiently transfer the heat of the isolation ring 51 to the heat sink 6.

[0043] 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 low-loss, high-efficiency resonant inductor structure, characterized in that, The magnetic core (1) includes a coil position (2) formed inside the magnetic core (1), a coil (3) is provided in the coil position (2), an upper core post (11) and a lower core post (12) are also provided inside the magnetic core (1), a magnetic core air gap (4) is provided between the upper core post (11) and the lower core post (12), the coil (3) is wound on the outside of the upper core post (11) and the lower core post (12), and an isolation member (5) is provided on the outside of the upper core post (11) and the lower core post (12), the isolation member (5) isolates the magnetic core air gap (4) from the coil (3).

2. The low-loss, high-efficiency resonant inductor structure according to claim 1, characterized in that, The isolation element (5) is an isolation ring (51), which has a hollow structure that covers the outside of the upper core post (11) and the lower core post (12) and covers the magnetic core air gap (4).

3. The low-loss, high-efficiency resonant inductor structure according to claim 2, characterized in that, The isolation ring (51) is made of engineering plastic.

4. The low-loss, high-efficiency resonant inductor structure according to claim 3, characterized in that, The two sides of the isolation ring (51) abut against the top and bottom walls of the coil position (2).

5. The low-loss, high-efficiency resonant inductor structure according to any one of claims 1-4, characterized in that, The magnetic core (1) includes an upper core seat (13) and a lower core seat (14) arranged opposite to each other, and the upper core post (11) and the lower core post (12) are respectively connected to the upper core seat (13) and the lower core seat (14). The upper core seat (13) and the lower core seat (14) are respectively provided with an upper core block (15) and a lower core block (16) on both sides. The upper core block (15) and the lower core block (16) are connected to each other to form a coil position (2) between the upper core seat (13) and the lower core seat (14).

6. The low-loss, high-efficiency resonant inductor structure according to claim 5, characterized in that, The upper core seat (13) is provided with a heat sink (6), and heat conduction pillars (7) are provided on both sides of the upper core seat (13). The heat conduction pillars (7) are connected to the heat sink (6), and the heat conduction pillars (7) extend to the coil position (2) and are attached to the isolation ring (51).

7. The low-loss, high-efficiency resonant inductor structure according to claim 6, characterized in that, The upper core seat (13) has slots (131) on both sides that communicate with the coil position (2), and the heat-conducting column (7) is fitted into the slots (131).

8. The low-loss, high-efficiency resonant inductor structure according to claim 7, characterized in that, A connecting plate (71) is attached to the upper surface of the upper core seat (13) between the two heat-conducting columns (7). A limiting groove (61) is opened on the lower end face of the heat sink (6), and the connecting plate (71) is fitted into the limiting groove (61).

9. The low-loss, high-efficiency resonant inductor structure according to claim 8, characterized in that, The connecting plate (71) has a positioning hole (72), and the limiting groove (61) has a positioning post (62) inserted into it.

10. The low-loss, high-efficiency resonant inductor structure according to claim 9, characterized in that, The heat sink (6) is made of aluminum. The heat-conducting column (7) is made of ceramic material.

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