Inductive component, inverter, motor controller and electrical consumer

Abstract

The application relates to an inductor assembly, an inverter, a motor controller and an electric device, comprising an inductor body and a heat dissipation component, at least one protrusion is arranged between the magnetic core and the heat dissipation component, the magnetic core is supported on the protrusion, and pouring glue is arranged between the magnetic core and opposite surfaces of the heat dissipation component on two sides of the protrusion. According to the inductor assembly provided by the application, the heat of the inductor body is mainly transmitted to the heat dissipation component through the pouring glue, and the heat dissipation efficiency of the inductor assembly is effectively improved.

Description

Technical Field

[0001] This application relates to the field of inductor technology, and more particularly to an inductor component, an inverter, a motor controller, and an electrical device. Background Technology

[0002] Inductors are crucial components in electronic circuits, primarily used for energy storage (in the form of magnetic fields), filtering, tuning, impedance matching, and suppressing electromagnetic interference (EMI). Inductors generally consist of a coil and a magnetic core; however, the heat dissipation efficiency of inductors in current technologies still needs improvement. Utility Model Content

[0003] This application provides an inductor component that can improve the heat dissipation efficiency of the inductor component, thereby at least partially solving the above-mentioned technical problems.

[0004] To achieve the above objectives, according to a first aspect of this application, an inductor assembly is provided, comprising:

[0005] The inductor includes an inductor body, the inductor body including at least one magnetic core; a heat dissipation component connected to the inductor body, at least one protrusion between the magnetic core and the heat dissipation component, the magnetic core being supported on the protrusion, and potting compound being disposed between the magnetic core and the heat dissipation component on opposite sides of the protrusion.

[0006] Optionally, the inductor body includes a coil wound around the circumference of a magnetic core, and the magnetic core has opposing end faces along its axial direction, one of the end faces being disposed on the protrusion.

[0007] Optionally, the protrusion and the magnetic core are integrally formed, or the protrusion and the heat dissipation component are integrally formed.

[0008] Optionally, the protrusion is strip-shaped and extends along the surface of the magnetic core or heat dissipation component; or, the protrusion is dot-shaped.

[0009] Optionally, the protrusion is strip-shaped, and the protrusion is in line contact or near-line contact with the magnetic core or the heat dissipation component, and / or the cross-section of the protrusion is one of the following shapes: circular or triangular, or a combination of semicircle and square, with the arc edge of the semicircle facing away from the square, or a combination of triangle and square, with one corner of the triangle facing away from the square.

[0010] Optionally, there are multiple protrusions, and the projection of the center of the magnetic core onto the surface of the heat dissipation component is within the area enclosed by the multiple protrusions.

[0011] Optionally, there may be multiple magnetic cores arranged side by side.

[0012] Optionally, the heat dissipation component includes a heat dissipation base plate, the heat dissipation base plate has opposite sides, and the protrusion is disposed on one side of the heat dissipation base plate.

[0013] Optionally, the other side of the heat dissipation base plate is provided with heat dissipation fins, or the heat dissipation base plate is provided with a flow channel for transmitting cooling medium.

[0014] Optionally, the inductor assembly further includes a housing with openings at both ends. One end of the housing with the opening abuts against the heat dissipation component, and the protrusion is disposed in the opening area. The housing has a receiving cavity that communicates with the openings. The inductor body is at least partially disposed in the receiving cavity, and potting compound is disposed inside the housing.

[0015] Optionally, the shell is a hollow cylindrical shell with open ends in the axial direction, and the interior has a continuously penetrating receiving cavity.

[0016] According to a second aspect of this application, an inverter is provided, including the inductor component as described above.

[0017] According to a third aspect of this application, a motor controller is provided, including the inductor assembly described above, or including the inverter described above.

[0018] According to a fourth aspect of this application, an electrical appliance is provided, comprising an inductor assembly as described above, or an inverter as described above, or a motor controller as described above.

[0019] The inductor assembly of this application embodiment provides a raised support core, which facilitates the application of potting compound between the magnetic core and the heat dissipation component on opposite sides of the raised support core. This allows more heat from the inductor body to be transferred to the heat dissipation component through the potting compound, thereby improving the heat dissipation efficiency of the inductor assembly.

[0020] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0023] Figure 1This is a schematic diagram of the structure of an inductor assembly according to an embodiment of this application;

[0024] Figure 2 This is a partial cross-sectional schematic diagram of an inductor assembly according to another embodiment of this application;

[0025] Figure 3 This is a partial structural schematic diagram of an inductor assembly according to another embodiment of this application;

[0026] Figure 4 This is a partial structural schematic diagram of an inductor assembly according to another embodiment of this application.

[0027] Explanation of reference numerals in the attached figures:

[0028] 1. Inductor body; 2. Heat dissipation component; 3. Protrusion; 4. Housing; 11. Magnetic core; 12. Coil; 21. Heat dissipation base plate; 22. Heat dissipation fins. Detailed Implementation

[0029] The embodiments of this application 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 application, and should not be construed as limiting this application.

[0030] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application 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, and therefore should not be construed as a limitation of this application.

[0031] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0032] The applicant has discovered that in related technologies, inductor components typically achieve heat dissipation through direct contact between a heat sink and the magnetic core. However, due to the uneven surfaces of the heat sink and the magnetic core, the contact surfaces are difficult to fit perfectly, resulting in gaps between them. Air is the primary heat conduction medium in these gaps. Air has low thermal conductivity, thus the contact thermal resistance between the magnetic core and the heat sink is relatively high, affecting the heat dissipation efficiency of the inductor component. Especially in high-power or high-density integrated applications, this low heat dissipation efficiency leads to increased operating temperature of the inductor component, thereby affecting its performance and lifespan.

[0033] Therefore, embodiments of this application provide an inductor component, such as... Figure 1 As shown, the inductor assembly includes an inductor body 1 and a heat dissipation component 2. The inductor body 1 includes at least one magnetic core 11. The heat dissipation component 2 is connected to the inductor body 1. At least one protrusion 3 is provided between the magnetic core 11 and the heat dissipation component 2. The magnetic core 11 is supported on the protrusion 3. A potting compound (not shown in the figure) is provided between the magnetic core 11 and the heat dissipation component 2 on opposite sides of the protrusion 3.

[0034] In the above embodiment, by providing at least one protrusion 3 between the magnetic core 11 and the heat dissipation component 2, and supporting the magnetic core 11 on the protrusion 3, a gap is created between the magnetic core 11 and the heat dissipation component 2 on opposite sides of the protrusion 3. This facilitates the application of potting compound between the magnetic core 11 and the heat dissipation component 2, allowing more heat from the inductor body 1 to be transferred to the heat dissipation component 2 through the potting compound. The potting compound can be applied by filling or other methods commonly used by those skilled in the art. The potting compound is a commonly used potting compound in the art, such as silicone potting compound, polyurethane potting compound, epoxy resin potting compound, etc. Since the thermal conductivity of the potting compound (the thermal conductivity of the potting compound in the inductor is usually ≥1 W / (m·K)) is much greater than that of air (approximately 0.024 W / (m·K)), it can reduce contact thermal resistance and improve the heat dissipation efficiency of the inductor component.

[0035] It is understood that the height H of the protrusion 3 can be designed according to the viscosity or thixotropic properties of the potting compound, and should at least ensure that the potting compound can be placed between the opposing surfaces of the magnetic core 11 with the protrusion and the heat dissipation component 2, so that the potting compound can be placed in the gap between the magnetic core 11 and the heat dissipation component 2. The height of the protrusion 3 is, for example, 1mm, 1.5mm, 2mm, or any value within the range of the above values.

[0036] To meet the basic performance requirements of the inductor assembly, the material of the protrusion 3 can be selected as needed, for example, the protrusion 3 can be made of insulating material.

[0037] In some embodiments, the inductor body 1 includes a coil 12 wound around the magnetic core 11 circumferentially, and the magnetic core 11 has opposing end faces along its axial direction, one of the end faces being disposed on the protrusion 3.

[0038] In the above embodiments, such as Figure 2 As shown, the coil 12 is wound circumferentially around the magnetic core 11, and the axial direction of the magnetic core 11 is arranged along a first direction. One end of the magnetic core 11, along its axial direction, near the heat dissipation component 2, is disposed on the protrusion 3. The first direction is the vertical direction. The magnetic core 11 has two opposite end faces along its axial direction, and the end face of the magnetic core 11, along its axial direction, near the heat dissipation component 2, is disposed on the protrusion 3. By having one end face of the magnetic core 11 disposed on the protrusion 3, collisions between the coil 12 and the protrusion 3 can be avoided, thereby protecting the coil 12 and preventing its electromagnetic performance from being affected.

[0039] In some embodiments, the protrusion 3 and the magnetic core 11 are integrally formed, or the protrusion 3 and the heat dissipation component 2 are integrally formed. This integrated design reduces the assembly steps of the inductor assembly and simplifies the manufacturing process.

[0040] It is understood that the protrusion 3 and the magnetic core 11 can be fixedly connected first. The protrusion 3 is connected to the magnetic core 11 by adhesive bonding or by other commonly used methods in the art. Then, potting compound is applied between the magnetic core 11 and the heat dissipation component 2.

[0041] Specifically, the two opposite ends of the magnetic core 11 along the axial direction are usually designed as planes, and the protrusion 3 can be easily fixed on the end face of the magnetic core 11.

[0042] Alternatively, the protrusion 3 and the heat dissipation component 2 can be fixedly connected first, and then potting compound can be applied between the magnetic core 11 and the heat dissipation component 2. The protrusion 3 and the heat dissipation component 2 can be connected by adhesive or screws, or by other methods commonly used in the art; or, the protrusion 3 and the heat dissipation component 2 can be integrally formed, which simplifies the manufacturing process.

[0043] In some embodiments, the protrusion 3 is strip-shaped and extends along the surface of the magnetic core 11 or the heat dissipation component 2; or the protrusion 3 is dot-shaped. By designing protrusions 3 of different shapes, it is possible to accommodate magnetic cores 11 of different sizes and shapes, providing sufficient space for potting compound, while the manufacturing process is relatively simple.

[0044] It is understood that the protrusion 3 is strip-shaped, for example, a straight strip, such as... Figure 3As shown, the protrusions 3 may be curved strips extending along the surface of the magnetic core 11 or the heat dissipation component 2. Alternatively, the protrusions 3 may be dot-shaped. Specifically, the protrusions 3 can be cylinders, frustums, cones, hemispheres, or other structures understood by those skilled in the art that protrude from the surface of the heat dissipation component 2 or one end face of the magnetic core 11. Different shapes of the protrusions 3 can be selected according to the size and shape of the magnetic core 11. Whether strip-shaped or dot-shaped, they occupy a smaller area compared to the surface of the magnetic core 11, leaving more space for potting compound and facilitating heat dissipation of the inductor assembly; at the same time, the manufacturing process is relatively simple.

[0045] In some embodiments, the protrusion 3 is strip-shaped, and the protrusion 3 makes line contact with the magnetic core 11 or the heat dissipation component 2. This line contact or near-line contact reduces the contact area between the protrusion 3 and the magnetic core 11 or the heat dissipation component 2, facilitating the filling of gaps with potting compound and allowing more potting compound to be placed between the magnetic core 11 and the heat dissipation component 2, thereby transferring more heat from the magnetic core to the heat dissipation component 2 through the potting compound. For ease of processing, the cross-section of the protrusion 3 is one of the following shapes: circular or triangular, or a combination of semicircle and square, with the arc edge of the semicircle facing away from the square, or a combination of triangle and square, with one corner of the triangle facing away from the square.

[0046] It is understood that, according to conventional techniques used by those skilled in the art, the cross-section of the protrusion 3 can be either circular or approximately circular, triangular or approximately triangular, and square or rectangular.

[0047] In some embodiments, there are multiple protrusions 3, and the projection of the center of the magnetic core 11 onto the surface of the heat dissipation component 2 lies within the area enclosed by the multiple protrusions 3. The support design of the multiple protrusions 3 disperses the pressure on the magnetic core 11, making the support of the protrusions 3 more stable and improving structural stability.

[0048] It is understood that there are multiple protrusions 3. For example, the protrusions 3 may be straight strips, extending along the second direction, or there may be two protrusions 3 arranged side-by-side and spaced apart along a third direction. The second direction intersects the third direction, and the projection of the center of the magnetic core 11 onto the surface of the heat dissipation component 2 falls within the area between the two protrusions 3. By setting two straight protrusions 3, the pressure of the magnetic core 11 is distributed on the two straight protrusions 3, which makes the support of the protrusions 3 more stable and improves the structural stability.

[0049] In some embodiments, the number of magnetic cores 11 is multiple, and the multiple magnetic cores 11 are arranged side by side. This scheme can improve the power density of the inductor by using a multi-core 11 side by side design.

[0050] It is understood that there are multiple magnetic cores 11, such as two, with the two magnetic cores 11 arranged side by side. Each magnetic core 11 is supported on the protrusion 3, which can improve the power density of the inductor. At the same time, the structure of the protrusion 3 ensures that potting compound can be applied between each magnetic core 11 and the heat dissipation component 2 to improve the heat dissipation efficiency of the inductor assembly.

[0051] In some embodiments, the heat dissipation component 2 includes a heat dissipation base plate 21, which has two opposing sides, and the protrusion 3 is disposed on one side of the heat dissipation base plate 21. The structural design of the heat dissipation base plate 21 provides a stable mounting foundation for the protrusion 3.

[0052] Furthermore, a heat dissipation fin 22 is provided on the other side of the heat dissipation base plate 21, or a flow channel for transmitting the cooling medium is provided inside the heat dissipation base plate 21. By providing heat dissipation fins 22 or cooling medium flow channels, a multi-stage heat dissipation structure is formed, which can enhance the heat dissipation capacity of the heat dissipation component 2.

[0053] It is understood that the heat dissipation base plate 21 has a protrusion 3 on one side and heat dissipation fins 22 on the other side. A potting compound is placed between the magnetic core 11 and the heat dissipation base plate 21. The heat from the magnetic core 11 can be transferred to the heat dissipation base plate 21 through the potting compound. Since the heat dissipation fins 22 have a large heat dissipation area, the heat is effectively dissipated through the fins. Alternatively, the heat dissipation base plate 21 can have channels for transporting cooling medium. The heat from the magnetic core 11 can be transferred to the heat dissipation base plate 21 through the potting compound, and then dissipated through the cooling medium within the channels. Therefore, by forming a multi-stage heat dissipation structure through the heat dissipation fins 22 or the cooling medium channels, the heat dissipation capacity of the heat dissipation component 2 can be enhanced.

[0054] In some embodiments, such as Figure 4 As shown, the inductor assembly also includes a housing 4, with openings at both ends. One end of the housing 4 with an opening abuts against the heat dissipation component 2, and the protrusion 3 is disposed in the opening area. The housing 4 has a receiving cavity that communicates with the openings, and the inductor body 1 is at least partially disposed within the receiving cavity. Encapsulating resin is disposed inside the housing 4. The housing 4's structural design protects the inductor assembly from external environmental influences while providing space for the encapsulating resin.

[0055] It is understood that the inductor assembly also includes a housing 4, which has openings at both ends. One end of the housing 4 with an opening abuts against the heat dissipation component 2, and the protrusion 3 is disposed in the opening area. The opening at the end can be fully open or only partially open. The end of the housing 4 that abuts against the heat dissipation component 2 can be connected to the heat dissipation component 2 by bonding or welding, or by other means commonly used in the art. The housing 4 has a receiving cavity that communicates with the opening. The inductor body 1 is at least partially disposed within the receiving cavity, and potting compound is disposed inside the housing 4. The inductor body 1 includes at least one magnetic core 11, which has two opposing ends. The magnetic core 11 is at least partially disposed within the receiving cavity, with one end of the magnetic core 11 supported on the protrusion 3. The other end of the magnetic core 11 can extend out of the receiving cavity through the opening, or the other end of the magnetic core 11 can also be disposed within the receiving cavity, which can be designed according to actual needs. Since the inductor body 1 is at least partially disposed within the housing 4, the housing 4 can protect the inductor body 1 from external environmental influences. In addition, since potting compound needs to be placed between the inductor body 1 and the heat dissipation component 2, the housing 4 can provide space for the potting compound, making it easier to place the potting compound.

[0056] In some embodiments, the housing 4 is a hollow cylindrical housing 4 with open ends along the axial direction, and the housing 4 has a continuously penetrating receiving cavity inside. The cylindrical housing 4 design simplifies the assembly process.

[0057] It is understood that the housing 4 is a hollow cylindrical shape, and the cross-section can be circular, triangular, quadrilateral or polygonal. The two ends of the housing 4 are open in the axial direction. The housing 4 has a continuous through cavity inside. The housing 4 has a simple structure, which can simplify the assembly process of the inductor component.

[0058] This application also provides an inverter that includes the aforementioned inductor component.

[0059] Understandably, the heat dissipation component 2 can transfer the heat of the inductor body 1 to the outside. By setting the protrusion 3, the magnetic core 11 is supported on the protrusion 3. The magnetic core 11 and the heat dissipation component 2 are provided with potting compound between their opposite sides on both sides of the protrusion 3. The potting compound can transfer the heat of the inductor body 1 to the heat dissipation component 2, which effectively improves the heat dissipation efficiency of the inductor component and thus ensures that the inverter can work stably.

[0060] This application also provides a motor controller, which includes the aforementioned inductor component or inverter. By employing a highly efficient heat-dissipating inductor component, the operational stability of the motor controller can be improved, and the service life of the equipment can be extended.

[0061] This application also provides an electrical device, which includes the aforementioned inductor component, inverter, or motor controller. This electrical device can be a conventional electrical device in the art, such as a gasoline-powered vehicle, a hybrid vehicle, a pure electric vehicle, a forklift, or a drone, energy storage power station, etc., and is not particularly limited thereto. By employing an inductor component with high-efficiency heat dissipation, the operational stability of the electrical device can be improved.

[0062] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0063] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0064] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0065] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. An inductor component, characterized in that, include: An inductor body, the inductor body comprising at least one magnetic core; A heat dissipation component is connected to the inductor body. At least one protrusion is provided between the magnetic core and the heat dissipation component. The magnetic core is supported on the protrusion. Encapsulating adhesive is provided between the magnetic core and the opposite surfaces of the heat dissipation component on both sides of the protrusion.

2. The inductor assembly according to claim 1, characterized in that, The inductor body includes a coil wound around a magnetic core circumferentially. The magnetic core has two opposing end faces along its axial direction, one of which is disposed on the protrusion.

3. The inductor assembly according to claim 1, characterized in that, The protrusion and the magnetic core are integrally formed, or the protrusion and the heat dissipation component are integrally formed.

4. The inductor assembly according to claim 1, characterized in that, The protrusion is strip-shaped and extends along the surface of the magnetic core or the heat dissipation component; or, the protrusion is dot-shaped.

5. The inductor assembly according to claim 4, characterized in that, The protrusion is strip-shaped, and the protrusion is in line contact or near-line contact with the magnetic core or the heat dissipation component; and / or, the cross-section of the protrusion is one of the following shapes: circular or triangular, or a combination of semicircle and square, with the arc edge of the semicircle facing away from the square, or a combination of triangle and square, with one corner of the triangle facing away from the square.

6. The inductor assembly according to claim 1, characterized in that, The protrusions are multiple, and the center of the magnetic core is projected onto the surface of the heat dissipation component within the area enclosed by the multiple protrusions.

7. The inductor assembly according to claim 1, characterized in that, The number of magnetic cores is multiple, and the multiple magnetic cores are arranged side by side.

8. The inductor assembly according to claim 1, characterized in that, The heat dissipation component includes a heat dissipation base plate, which has two opposing sides, and the protrusion is disposed on one side of the heat dissipation base plate.

9. The inductor assembly according to claim 8, characterized in that, The heat dissipation base plate is provided with heat dissipation fins on the other side, or the heat dissipation base plate is provided with flow channels for transmitting cooling medium.

10. The inductor assembly according to any one of claims 1 to 9, characterized in that, The inductor assembly further includes a housing with openings at both ends. One end of the housing with the opening abuts against the heat dissipation component, and the protrusion is disposed in the opening area. The housing has a receiving cavity that communicates with the opening. The inductor body is at least partially disposed in the receiving cavity, and potting compound is disposed inside the housing.

11. The inductor assembly according to claim 10, characterized in that, The shell is a hollow cylindrical shell with open ends along the axis, and has a continuously penetrating receiving cavity inside.

12. An inverter, characterized in that, Including the inductor assembly as described in any one of claims 1 to 11.

13. A motor controller, characterized in that, Includes the inductor assembly as described in any one of claims 1 to 11, or includes the inverter as described in claim 12.

14. An electrical appliance, characterized in that, It includes the inductor assembly as described in any one of claims 1 to 11, or the inverter as described in claim 12, or the motor controller as described in claim 13.

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