Magnetic assembly integrated inductor with filtering function

Abstract

The utility model relates to the technical field of magnetic combination integrated inductance, disclose a kind of magnetic combination integrated inductance with filtering function, including No. 1 magnetic core, No. 2 magnetic core and inductance winding, No. 1 magnetic core and No. 2 magnetic core are engaged and cover and are arranged on inductance winding, the outer wall both sides of inductance winding are fixedly covered with insulating tape, the outer wall of inductance winding is fixedly covered with adhesive copper foil, inductance winding is fixedly covered with NOMEX insulating paper, the inner wall of the both sides of adhesive copper foil respectively with the outer wall of two insulating tapes is attached and is arranged, the both sides outer wall of adhesive copper foil respectively with two insulating tapes is attached and is arranged, the lower end surface of No. 1 magnetic core is fixedly connected with base, the base is threadedly covered with a plurality of positioning needles.The utility model in, magnetic core uses three groups EE type metal powder core bonding and is formed, effectively promotes the bearing capacity of inductance coil, guarantees the stable effective work of inductance, while flat wire coil periphery is wrapped adhesive copper foil, effectively reduces electromagnetic interference noise.

Description

Technical Field

[0001] This utility model relates to the field of magnetic composite integrated inductor technology, and in particular to a magnetic composite integrated inductor with filtering function. Background Technology

[0002] Magnetic integrated inductors are a type of inductor based on magnetic integration technology, which winds two or more discrete inductors and other magnetic components onto the same magnetic core. The aim is to significantly reduce the size and weight of magnetic components, lower current ripple, reduce magnetic losses, and improve the dynamic performance of the power supply, thereby enhancing the power supply's performance and power density.

[0003] The inductor structure of existing devices with winding methods generally lacks consistency, and traditional ferrite cores require additional air gaps to improve the product's loading capacity. This cannot avoid the problem of localized overheating at the air gap location due to core wire cutting during operation. In addition, traditional PFC inductors generate significant electromagnetic interference noise due to magnetic field changes caused by current variations during frequency modulation, resulting in low efficiency.

[0004] Therefore, those skilled in the art have provided a magnetically integrated inductor with filtering function to solve the problems mentioned in the background art. Utility Model Content

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a magnetically integrated inductor with filtering function. The winding coil is manufactured using a vertical winding method, which simplifies the process, reduces instability caused by manual operation, and simplifies the assembly of the coil and magnetic core. The coil is wrapped with insulating tape, and NOMEX is placed in the middle.

[0006] The magnetic core is directly mounted after the insulating paper, which greatly improves production efficiency. At the same time, after the coil leads out and the solder is removed, it is inserted into the corresponding PIN hole on the base plate and fixed by adhesive application, which reduces the wire wrapping and soldering process at the lead-out point and improves the reliability of the product soldering.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A magnetically integrated inductor with filtering function includes a first magnetic core, a second magnetic core, and an inductor winding. The first and second magnetic cores are snapped onto the inductor winding. Insulating tape is fixedly sleeved on both sides of the outer wall of the inductor winding. Adhesive-backed copper foil is fixedly sleeved on the outer wall of the inductor winding. NOMEX insulating paper is fixedly sleeved inside the inductor winding.

[0009] Through the above technical solution, the No. 1 magnetic core and the No. 2 magnetic core are engaged to form a closed magnetic field, ensuring efficient magnetic field conduction and reducing magnetic energy loss. The insulating tape provides basic insulation between the inductor winding and the magnetic core, avoiding the risk of leakage. The adhesive copper foil acts directly on the outer wall of the winding, accurately shielding the electromagnetic waves generated by the winding and solving the EMI noise problem of traditional inductors. NOMEX insulating paper is placed inside the winding to further enhance the insulation performance, while also withstanding the temperature rise during inductor operation, avoiding aging and failure of the insulation material, and ensuring the safe operation of the inductor under high power conditions.

[0010] Furthermore, the inner walls on both sides of the adhesive-backed copper foil are respectively bonded to the outer walls of the two insulating tapes;

[0011] Through the above technical solution, the insulating tape can isolate the adhesive copper foil from the metal part of the inductor winding, avoiding direct contact between the adhesive copper foil and the winding, which could lead to a short circuit. At the same time, the close fit ensures that the adhesive copper foil can tightly wrap the winding, maximizing the contact area, improving the absorption and reflection efficiency of electromagnetic waves, ensuring the uniformity of the shielding and filtering effect, and avoiding local electromagnetic leakage caused by gaps.

[0012] Furthermore, the two outer walls of the adhesive-backed copper foil are respectively bonded to two insulating tapes;

[0013] Through the above technical solution, the outer insulating tape can protect the adhesive copper foil from frictional damage to the magnetic core, while preventing the adhesive copper foil from contacting the metal parts of the magnetic core, thus avoiding the formation of an additional conductive circuit that would affect inductance performance. Furthermore, the adhesive bonding also fills the gap between the adhesive copper foil and the magnetic core, reducing magnetic field loss in the gap.

[0014] Improve the energy conversion efficiency of the inductor while taking into account both shielding effect and magnetic stability.

[0015] Furthermore, a base is fixedly connected to the lower end face of the first magnetic core, and multiple positioning pins are threaded onto the base;

[0016] Through the above technical solution, the epoxy resin base has good insulation and structural strength. It can not only fix the No. 1 magnetic core, but also isolate the magnetic core from the risk of conductivity between the magnetic core and the external circuit board. The positioning pin is fixed to the base by threads, which can accurately align with the mounting holes of the circuit board of the whole machine, realize the rapid positioning and installation of the inductor, avoid the positional deviation during manual installation, and at the same time, the threaded connection facilitates disassembly and adjustment during later maintenance, improving assembly efficiency and stability.

[0017] Furthermore, a protective cover is fixedly connected to the upper end face of the second magnetic core, and the lower end face of the protective cover is fixedly connected to the upper end face of the base.

[0018] Through the above technical solution, the protective cover and the base form a closed space, which encloses the core components such as the magnetic core and windings, effectively blocking external dust, moisture and mechanical impact from damaging the internal structure, extending the service life of the inductor. At the same time, the closed structure can further constrain the magnetic field, reduce the outward radiation of the magnetic field, help enhance the EMI shielding effect, and ensure the stable operation of the inductor in complex working environments.

[0019] Furthermore, both the first and second magnetic cores are made of three EE-type metal powder cores bonded together;

[0020] Through the above technical solution, the distributed air gap inside the metal powder core can improve the inductance loading capacity without the need for an additional air gap, avoiding the problem of local high temperature after opening an air gap in traditional ferrite cores. (Three EE-type cores)

[0021] The bonded structure significantly increases the magnetic core's magnetic permeability and overall structural strength, enhancing the inductor's load capacity and adapting to the high current demands of high-power charging devices. Meanwhile, the distributed air gap makes the coil's eddy current losses negligible during inductor operation, significantly reducing product temperature rise and ensuring the stability of the inductor's long-term high-power operation.

[0022] Furthermore, the base is made of epoxy resin material;

[0023] Through the above technical solutions, epoxy resin material has excellent high temperature resistance, insulation and corrosion resistance, which can adapt to the high temperature environment inside high-power charging equipment, avoid the base from becoming loose due to high temperature aging, and at the same time, the good insulation can prevent the base from becoming a conductive path, avoid the risk of leakage, ensure the electrical safety of the inductor and the circuit board of the whole machine, and take into account both structural support and electrical protection functions.

[0024] This utility model has the following beneficial effects:

[0025] This invention proposes a magnetically integrated inductor with filtering function. The winding coil is manufactured using a vertical winding method, which simplifies the process, reduces the instability of manual operation, and simplifies the assembly of the coil and the magnetic core. The coil is wrapped with insulating tape, and the magnetic core is directly mounted after NOMEX insulating paper is placed in the middle, which greatly improves production efficiency. At the same time, after the coil leads are stripped of varnish and soldered, they are inserted into the corresponding PIN holes on the base plate and fixed by adhesive application, which reduces the wire wrapping and soldering process at the lead wires and improves the reliability of the product soldering. In addition, the copper foil backing tightly wraps the winding, which effectively eliminates EMI noise by reflecting and absorbing electromagnetic waves. Attached Figure Description

[0026] Figure 1 is an axial view of a magnetically combined integrated inductor with filtering function proposed in this utility model;

[0027] Figure 2 is a bottom-view axial side view of a magnetically combined integrated inductor with filtering function proposed in this utility model.

[0028] Figure 3 is an exploded view of a magnetically combined integrated inductor with filtering function proposed in this utility model.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. Base; 2. Magnetic core No. 1; 3. Adhesive-backed copper foil; 4. Inductor winding; 5. NOMEX insulating paper; 6. Magnetic core No. 2; 7. Protective cover; 8. Positioning pin; 9. Insulating tape. Detailed Implementation

[0031] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of specific embodiments. Obviously, the described specific embodiments are only a part of the specific embodiments of the present invention, and not all of them. Based on the specific embodiments of the present invention, all other specific embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Referring to Figures 1, 2, and 3, this utility model provides a specific embodiment: a magnetically integrated inductor with filtering function, comprising a first magnetic core 2, a second magnetic core 6, and an inductor winding 4. The first magnetic core 2 and the second magnetic core 6 are engaged and sleeved on the inductor winding 4. Insulating tape 9 is fixedly sleeved on both sides of the outer wall of the inductor winding 4. Adhesive-backed copper foil 3 is fixedly sleeved on the outer wall of the inductor winding 4. NOMEX insulating paper 5 is fixedly sleeved inside the inductor winding 4. The first magnetic core 2 and the second magnetic core 6 engage to form a closed magnetic field, ensuring efficient magnetic field conduction and reducing magnetic energy loss. The insulating tape 9 provides basic insulation between the inductor winding 4 and the magnetic cores, avoiding the risk of leakage. The adhesive-backed copper foil 3 directly acts on the outer wall of the winding, accurately shielding the electromagnetic waves generated by the winding, solving the EMI noise problem of traditional inductors. NOMEX insulating paper 5... It is sleeved inside the winding to further enhance the insulation performance, while also withstanding the temperature rise during inductor operation, preventing the insulation material from aging and failing, and ensuring the safe operation of the inductor under high power conditions. The inner walls of the two sides of the adhesive-backed copper foil 3 are respectively attached to the outer walls of the two insulating tapes 9.

[0033] The insulating tape 9 isolates the adhesive copper foil 3 from the metal part of the inductor winding 4, preventing the copper foil 3 from directly contacting the winding and causing a short circuit. Simultaneously, the adhesive tape ensures that the copper foil 3 tightly wraps the winding, maximizing the contact area, improving electromagnetic wave absorption and reflection efficiency, ensuring uniform shielding and filtering effects, and preventing localized electromagnetic leakage due to gaps. Two insulating tapes 9 are attached to the outer walls of the two sides of the copper foil 3. The outer insulating tape 9 protects the copper foil 3 from frictional damage from the magnetic core and prevents contact between the copper foil 3 and the metal part of the magnetic core, avoiding the formation of additional conductive loops that affect inductor performance. Furthermore, the adhesive tape fills the gap between the copper foil 3 and the magnetic core, reducing magnetic field loss in the gap.

[0034] To improve the energy conversion efficiency of the inductor while ensuring both shielding effectiveness and magnetic stability, a base 1 is fixedly connected to the lower end of the first magnetic core 2. Multiple positioning pins 8 are threaded onto the base 1. The epoxy resin base 1 provides excellent insulation and structural strength, securing the first magnetic core 2 and isolating it from the conductive risks of the external circuit board. The positioning pins 8, threaded onto the base 1, precisely align with the mounting holes on the circuit board, enabling rapid inductor positioning and installation, preventing positional misalignment during manual installation. The threaded connection also facilitates disassembly and adjustment for later maintenance, improving assembly efficiency and stability. A protective cover 7 is fixedly connected to the upper end of the second magnetic core 6. The lower end of the protective cover 7 is fixedly connected to the upper end of the base 1. The protective cover 7 and the base 1 form a closed space, enclosing the core, windings, and other core components. This effectively prevents damage to the internal structure from external dust, moisture, and mechanical impact, extending the inductor's lifespan. The enclosed structure further confines the magnetic field, reducing outward radiation and enhancing EMI shielding. The shielding effect ensures stable operation of the inductor in complex working environments. Both core 2 (No. 1) and core 6 (No. 2) are composed of three EE-type metal powder cores bonded together. The distributed air gap inside the metal powder cores enhances the inductor's loading capacity without requiring additional air gaps, avoiding the localized high temperature problem associated with traditional ferrite cores that require air gaps. The bonded structure of three EE-type cores significantly increases the magnetic field area and overall structural strength, improving the inductor's load capacity and adapting to the high current demands of high-power charging devices. Simultaneously, the distributed air gap makes the eddy current losses in the coil negligible during operation, significantly reducing product temperature rise and ensuring the stability of long-term high-power operation. The base 1 is made of epoxy...

[0035] Made of resin material, epoxy resin has excellent high temperature resistance, insulation and corrosion resistance, which can adapt to the high temperature environment inside high-power charging equipment, prevent the base 1 from becoming loose due to high temperature aging, and at the same time, the good insulation can prevent the base 1 from becoming a conductive path, avoid the risk of leakage, ensure the electrical safety of the inductor and the circuit board of the whole machine, and take into account both structural support and electrical protection functions.

[0036] Working principle: This device consists of three EE-type metal powder cores bonded together, namely magnetic core No. 1 and magnetic core No. 2.

[0037] 6. After engagement, a closed magnetic field circuit is formed to prevent magnetic field leakage. The inductor winding 4, made of flat wire, serves as the working magnetic field winding. When current is applied, a stable magnetic field is generated in the closed magnetic core circuit, realizing the basic power conversion function of the PFC inductor. The adhesive copper foil 3 wrapped around the outer wall of the inductor winding 4 utilizes its shielding properties to reflect and absorb the electromagnetic waves generated when the inductor winding 4 is working, and to suppress external electromagnetic interference, thereby eliminating EMI noise. The NOMEX insulating paper 5 inside the inductor winding 4 and the insulating tape 9 on the outer wall form double insulation protection to avoid the risk of leakage between the winding and the magnetic core. The epoxy resin base 1 fixes the magnetic core and winding with positioning pins 8 to ensure the stability of the overall structure. The protective cover 7 further isolates external dust and impact, ensuring the long-term stable operation of the inductor.

[0038] The following points should be noted in this article:

[0039] 1. The accompanying drawings of the embodiments disclosed herein only relate to the structures involved in the embodiments disclosed herein; other structures can be referred to in a general design.

[0040] 2. Where there is no conflict, the embodiments of this disclosure and the features in the embodiments can be combined with each other to obtain new embodiments.

[0041] Finally, it should be noted that the above description is only a preferred embodiment of this utility model and is not intended to limit this utility model. Although the utility model has been described in detail with reference to the foregoing specific embodiments, those skilled in the art can still understand the meaning of the foregoing specific embodiments.

[0042] Any modifications, equivalent substitutions, or improvements made to the technical solution or some of its technical features within the spirit and principles of this utility model shall be included within the protection scope of this utility model.

Claims

1. A magnetically integrated inductor with filtering function, comprising a first magnetic core (2), a second magnetic core (6), and an inductor winding (4), characterized in that: The first magnetic core (2) and the second magnetic core (6) are fitted together on the inductor winding (4). Insulating tape (9) is fixedly fitted on both sides of the outer wall of the inductor winding (4). Adhesive copper foil (3) is fixedly fitted on the outer wall of the inductor winding (4). NOMEX insulating paper (5) is fixedly fitted inside the inductor winding (4).

2. The magnetically integrated inductor with filtering function according to claim 1, characterized in that: The inner walls of the two sides of the adhesive copper foil (3) are respectively attached to the outer walls of the two insulating tapes (9).

3. The magnetically combined integrated inductor with filtering function according to claim 1, characterized in that: The two outer walls of the adhesive-backed copper foil (3) are respectively attached to two insulating tapes (9).

4. The magnetically combined integrated inductor with filtering function according to claim 1, characterized in that: The lower end face of the first magnetic core (2) is fixedly connected to a base (1), and multiple positioning pins (8) are threaded on the base (1).

5. The magnetically integrated inductor with filtering function according to claim 1, characterized in that: The upper end face of the second magnetic core (6) is fixedly connected to a protective cover (7), and the lower end face of the protective cover (7) is fixedly connected to the upper end face of the base (1).

6. The magnetically combined integrated inductor with filtering function according to claim 1, characterized in that: Both the first magnetic core (2) and the second magnetic core (6) are made of three EE type metal powder cores bonded together.

7. The magnetically combined integrated inductor with filtering function according to claim 4, characterized in that: The base (1) is made of epoxy resin material.

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