Inductor assembly, inductor heat dissipation structure, and converter

Abstract

The utility model discloses an inductance component, inductance heat dissipation structure, current transformer, this inductance component includes: inductance shell has a containing chamber, a plurality of inductance body, each inductance body is along with first direction and is arranged in containing chamber in proper order, a plurality of heat conduction spare, heat conduction spare is equipped with with inductance body's at least partial shape adaptation's contact portion, and through contact portion corresponding contact is arranged in a inductance body, heat conduction spare is equipped with at least one heat conduction portion by contact portion and extends along with second direction perpendicular to first direction, and heat conduction portion is in contact with the inner wall of inductance shell. This inductance component can have better heat dissipation effect.

Description

Technical Field

[0001] This utility model relates to the field of inductor component technology, specifically to an inductor component, an inductor heat dissipation structure, and a converter. Background Technology

[0002] In the field of power electronics, power inductors, as key energy storage and filtering components, are widely used in converters, inverters, power supplies, and other equipment. During operation, due to copper losses generated by current flowing through the windings and iron losses in the magnetic core under high-frequency magnetic fields, power inductors generate a large amount of heat, becoming a major heat source in the system. If this heat cannot be dissipated effectively and in a timely manner, it will lead to excessively high inductor temperatures, potentially causing aging of the winding insulation layer, degradation of the magnetic properties of the core material, and inductance value deviation, thereby affecting the performance, reliability, and lifespan of the entire power electronic equipment. Currently, a common encapsulation and heat dissipation method in the industry involves placing the inductor body, consisting of the inductor coil and magnetic core, inside a metal casing (usually aluminum or its alloy), and then injecting liquid potting compound (such as epoxy resin, polyurethane, or silicone) into the casing. After curing, the inductor body is completely encapsulated and fixed. In this structure, the potting compound mainly serves to provide electrical insulation, moisture and dust protection, and absorb mechanical vibration. Heat is generated from the inductor body, passes through the potting compound layer, and is conducted to the metal inductor casing, which has better thermal conductivity. Finally, it is transferred to the outside world through the contact between the inductor casing and an external heat sink (such as a liquid cooling plate). However, in traditional potted heat dissipation structures, the poor thermal conductivity of the potting compound material itself leads to the formation of a significant thermal resistance layer between the inductor coil and the metal inductor casing. Under high load operation of the power inductor, the heat dissipation effect of the inductor coil cannot meet the requirements. Utility Model Content

[0003] The purpose of this invention is to overcome the aforementioned defects or problems in the prior art and to provide an inductor component, an inductor heat dissipation structure, and a converter, wherein the inductor component can have a better heat dissipation effect.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] Technical Solution 1: An inductor assembly, comprising: an inductor housing having a receiving chamber; a plurality of inductor bodies, each of the inductor bodies being arranged sequentially in the receiving chamber along a first direction; a plurality of heat-conducting elements, each heat-conducting element having a contact portion adapted to at least a portion of the shape of the inductor body, and correspondingly contacting one of the inductor bodies through the contact portion; each heat-conducting element extending from the contact portion along a second direction generally perpendicular to the first direction having at least one heat-conducting portion, the heat-conducting portion contacting the inner wall of the inductor housing.

[0006] Technical Solution 2 based on Technical Solution 1: The inductor body includes an iron core and a coil wound on the iron core; the contact portion of the heat-conducting element is adapted to at least a portion of the outer peripheral wall of the coil so that the heat-conducting element is in contact with the coil.

[0007] Technical Solution 3 based on Technical Solution 2: The heat-conducting part of the heat-conducting component is provided with an extension part; the extension part is formed by extending from the part of the heat-conducting part that contacts the inner wall of the inductor housing in the same way as the inner wall of the inductor housing, so as to increase the contact area between the heat-conducting part and the inductor housing.

[0008] Technical Solution 4 based on Technical Solution 3: The iron core includes a shaft core passing through the coil and a side core surrounding the coil; the inductor housing has an opening at the top of its accommodating chamber; the heat-conducting element is disposed on the top of the inductor body, and its heat-conducting portion rests against the side core; the extension portion is located between the side core and the inner wall of the accommodating chamber.

[0009] Technical solution five based on technical solution two: The contact portion extends in a direction perpendicular to the axial direction of the coil to contact at least a portion of the top side of the coil and both sides in the first direction.

[0010] Technical solution six based on technical solution two: also includes several bottom heat-conducting blocks, which are correspondingly disposed between the bottom of an inductor body and the bottom wall of the accommodating chamber and are in contact with both.

[0011] Technical solution seven based on technical solution two: The inductor housing has a plurality of heat-conducting protrusions protruding from the inner surface of the bottom wall of the accommodating chamber; the protrusion shape of the heat-conducting protrusions is adapted to at least part of the shape of the bottom of the inductor body, so that the heat-conducting protrusions contact the corresponding inductor body.

[0012] Technical solution eight based on technical solution six: The heat-conducting component and the bottom heat-conducting block are made of heat-conducting ceramic material.

[0013] In addition, this utility model also provides technical solution nine: an inductive heat dissipation structure, which includes a heat sink, and further includes the inductive component described in any one of technical solutions one to eight, wherein the bottom wall of the inductive housing in the inductive component is in close contact with the heat dissipation surface of the heat sink.

[0014] In addition, this utility model also provides technical solution ten: a converter, including a power component and a heat sink, wherein at least a portion of the power component is cooled by the heat sink, and it further includes an inductor component as described in any one of technical solutions one to eight, wherein the bottom wall of the inductor housing in the inductor component is in close contact with the heat dissipation surface of the heat sink.

[0015] As can be seen from the above description of this utility model, compared with the prior art, this utility model has the following beneficial effects:

[0016] Technical Solution 1 provides an inductor assembly that establishes an efficient solid-state heat conduction path between the inductor body and the inductor shell by setting a heat-conducting component with a specific structure, thus improving the problem that the heat dissipation effect of the inductor coil in the prior art cannot meet the requirements. In the prior art, in order to achieve a compact structure, multiple inductor bodies are usually closely arranged in one direction within the same housing cavity of the inductor shell. This layout results in the sides of the inductor body located on the inside being blocked by adjacent inductor bodies, making it difficult for heat to be conducted laterally. At the same time, traditional heat dissipation methods rely on filling the housing cavity with potting compound, using the potting compound to conduct heat from the inductor body to the inductor shell. However, the thermal conductivity of the potting compound is usually very low, forming a significant thermal resistance between the heat source and the inductor shell, causing a large amount of heat to accumulate inside the inductor body and not be efficiently dissipated. This severely limits the power carrying capacity and long-term reliability of the inductor assembly.

[0017] The heat-conducting component used in this solution has a contact portion and a heat-conducting portion. The structural shape of the contact portion of the heat-conducting component is adapted to at least a portion of the shape of the inductor body, and the contact portion is positioned in contact with the inductor body, allowing the heat-conducting component to make direct contact with the inductor body over a large area with low thermal resistance, thereby efficiently collecting heat at the starting point of the heat conduction path. Structurally, the heat-conducting portion extends from the contact portion along a second direction, spanning the space between the inductor body and the inner wall of the inductor housing, and contacts the inner wall of the inductor housing, thereby establishing a direct physical connection between the inductor body and the inductor housing. Furthermore, through the structural design of the heat-conducting portion, each inductor body arranged in the inductor housing, whether located at both ends of the array or sandwiched in the middle, can establish the required heat conduction path without interference, thereby transferring heat laterally to the inductor housing. Compared to structures that establish heat conduction paths through heat-conducting components on both sides of the inductor body's axial direction, this design places the heat-conducting component along the axial direction of the inductor body. This heat-conducting component does not need to cross other inductor bodies to directly contact the inductor casing, allowing heat from all inductor bodies in the array to be quickly dissipated. Therefore, this design improves the uneven heat dissipation problem caused by the arrangement, resulting in a more balanced temperature distribution across the entire inductor assembly, significantly improving the overall heat dissipation performance and operational reliability under extreme conditions.

[0018] In technical solution two, the contact portion of the heat-conducting component is designed to be shape-fitted and in contact with the outer peripheral wall of the coil, which serves as the primary heat source. This design places the starting point of the heat conduction path directly at the location where heat generation is most concentrated. By matching the geometry of the contact portion with the outer periphery of the coil, a large-area, low-gap physical contact is formed between them, thereby minimizing interfacial thermal resistance and ensuring that heat generated on the coil surface is collected and transferred to the heat-conducting component immediately and efficiently. This avoids ineffective diffusion and accumulation of heat to other low-temperature components of the inductor (such as the iron core).

[0019] In technical solution three, an extension portion is provided on the heat-conducting part of the heat-conducting component, and the extension portion extends in the same way as the inner wall of the inductor housing. This significantly increases the effective contact area between the heat-conducting component and the inner wall of the inductor housing. The increased contact area can directly reduce the interfacial thermal resistance and increase the heat transfer flux per unit time, thereby improving the thermal conductivity. In addition, the thinner structure of the extension portion can effectively reduce the volume occupied by the heat-conducting component between the inductor body and the inner wall of the inductor housing, making it easier to install the heat-conducting component.

[0020] In technical solution four, the core of the inductor body is defined by a shaft core passing through the coil and side cores surrounding the coil, and the top of the accommodating cavity of the inductor shell is open. Based on this, a heat-conducting element is disposed on the top of the inductor body, with its heat-conducting portion resting against the side cores, and its extension portion located between the side cores and the inner wall of the accommodating cavity. The side cores, as the solid portion of the core located around the coil, are positioned precisely on the critical path between the coil's heat source and the inner wall of the inductor shell, and their top plane provides a stable and reliable contact reference surface for the heat-conducting element. By directly resting the heat-conducting portion against the side cores, the heat conduction path is ensured to precisely and efficiently penetrate the main channel for heat diffusion from the coil to the outside, avoiding increased thermal resistance due to unclear contact points (such as potential contact with the insulating frame or gaps). Furthermore, the extension portion is confined within the space between the side cores and the inner wall of the accommodating cavity, utilizing the natural gap formed between the side cores and the inner wall of the shell. By designing the extension section here, not only is full and reliable contact between the heat-conducting part and the inner wall of the housing achieved, but also no additional space is required or the main body size of the inductor body is changed. This solves the core problem that when multiple inductors are arranged side by side, the heat-conducting part cannot directly contact the inner wall of the housing due to the side core blocking.

[0021] In technical solution five, the contact portion not only contacts the top side of the coil but also extends in a direction perpendicular to the coil's axial direction, thus also contacting both sides of the coil in the first direction, achieving multi-faceted coverage of the coil. This wraparound contact structure, compared to contact only at the top, increases the effective area for heat collection and further improves heat dissipation efficiency.

[0022] In technical solution six, a bottom heat-conducting block is added, which fills the space between the bottom of the inductor body and the bottom wall of the accommodating chamber, directly thermally connecting the two. This structure, together with the top heat-conducting component, forms a three-dimensional heat dissipation structure that dissipates heat simultaneously from both the top and bottom of the inductor body. This design not only reduces the overall average temperature of the inductor body more quickly but also improves the internal temperature gradient, making the internal temperature distribution more uniform and avoiding the problem of localized overheating of the inductor body.

[0023] In technical solution seven, a heat-conducting protrusion adapted to the shape of the inductor body's bottom is directly provided on the bottom wall of the inductor casing. This protrusion also effectively dissipates heat from the bottom of the inductor body. Furthermore, compared to using a separate bottom heat-conducting block, this integrated structure reduces the number of components and assembly steps, simplifying the manufacturing process. Simultaneously, since the heat-conducting protrusion is part of the inductor casing, there is no interface thermal resistance between them, resulting in a more direct path for heat transfer from the bottom of the inductor body to the inductor casing, leading to higher heat conduction efficiency.

[0024] In technical solution eight, the heat-conducting component and the bottom heat-conducting block are made of thermally conductive ceramic. Thermally conductive ceramic materials possess extremely high thermal conductivity and excellent electrical insulation properties. High thermal conductivity is a prerequisite for ensuring that the constructed solid heat conduction path has extremely low thermal resistance. Excellent electrical insulation properties ensure that, under high-voltage operating conditions, the heat-conducting component, while acting as a thermal bridge, will not cause electrical short circuits. Thus, an efficient heat conduction path is constructed while ensuring electrical safety.

[0025] Technical solution nine provides an inductor heat dissipation structure, including the aforementioned inductor component and heat sink. The efficient heat dissipation design of the inductor component ensures that heat can be smoothly conducted from the coil to the flat bottom wall of the inductor casing. The tight fit between the bottom wall of the inductor casing and the heat sink ensures that this heat can be efficiently transferred to the heat sink and ultimately dissipated by it. This inductor heat dissipation structure can effectively improve the overall heat dissipation capacity of the inductor component.

[0026] Technical solution ten provides a converter that employs the aforementioned inductor heat dissipation structure. Applying this heat dissipation structure to the converter can improve the performance and reliability of the power inductor. Due to the significantly enhanced heat dissipation capacity of the inductor, its temperature rise is effectively controlled, allowing the converter to operate at higher switching frequencies or larger currents, thereby increasing the converter's power density and efficiency. Simultaneously, the improved inductor operating stability also enhances the long-term reliability and extends the lifespan of the entire converter system. When the inductor shares the same heat sink with other power components, this integrated heat dissipation design also helps simplify the overall heat dissipation system layout of the converter, optimizing system cost and size. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is an exploded view of the inductive heat dissipation structure according to an embodiment of the present utility model;

[0029] Figure 2 This is a schematic diagram of the assembly state of the inductive heat dissipation structure involved in the embodiment of this utility model;

[0030] Figure 3 for Figure 1 Schematic diagram of the structure of the heat-conducting component;

[0031] Figure 4 for Figure 2 Top view of the inductor heat dissipation structure;

[0032] Figure 5 for Figure 4 Schematic diagram of section AA;

[0033] Figure 6 for Figure 1 Schematic diagram of the inductor housing Figure 1 ;

[0034] Figure 7 for Figure 1 Schematic diagram of the inductor housing Figure 2 .

[0035] Explanation of key figure labels:

[0036] Inductor housing 100; accommodating chamber 101; bottom wall 110; first surface 111; second surface 112; thermally conductive protrusion 121; thermally conductive surface 122; side wall 130;

[0037] Inductor body 200; iron core 210; side core 211; shaft core 212; coil 220; bending part 221; bracket 230;

[0038] Radiator 300; Heat dissipation surface 310;

[0039] Heat-conducting component 400; contact portion 410; heat-conducting portion 420; extension portion 421; connecting arm 422. Detailed Implementation

[0040] 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 preferred embodiments of the present utility model and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0041] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and drawings of this utility model is for distinguishing different objects and not for describing a specific order.

[0042] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this utility model, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing this utility model and simplifying the description. It does 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 limiting the specific protection scope of this utility model.

[0043] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this utility model shall be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection through other devices or components.

[0044] In the claims, description and accompanying drawings of this utility model, the terms "comprising", "having", and variations thereof are used to mean "including but not limited to".

[0045] Example

[0046] This utility model embodiment relates to a converter, which includes a power component and a heat sink 300, with at least a portion of the power component dissipating heat through the heat sink 300. Specifically, a converter refers to a power electronic device used to convert electrical energy into its physical form. Typical applications include, but are not limited to, energy storage converters, photovoltaic inverters, electric vehicle drive systems, rail transit traction converters, and industrial uninterruptible power supplies (UPS). In these applications, the converter typically includes multiple power semiconductor devices (such as IGBTs and MOSFETs), DC bus capacitors, filter inductors, and control circuits. The power semiconductor devices are part of the aforementioned power component, which is one of the main heat sources in the converter. In this embodiment, the power semiconductor devices in the power component, such as the IGBT module, are dissipated heat through the heat sink 300. Furthermore, the power inductor, as a key power conversion element in the converter (such as the inverter inductor in the inverter circuit), generates significant copper and iron losses under high-frequency, high-current conditions, also becoming one of the main heat sources. In traditional structures, power inductors are often encapsulated with potting compound and then mounted on a heatsink 300. However, due to the low thermal conductivity of the potting compound, the thermal resistance is too high, which severely restricts the inductor's temperature rise control capability and the overall power density improvement of the system.

[0047] Furthermore, the converter also includes an inductor assembly, in which the bottom wall 110 of the housing is in close contact with the heat dissipation surface 310 of the heat sink 300. The heat sink 300 and the inductor assembly in the converter constitute an inductive heat dissipation structure. The heat dissipation surface 310 of the heat sink 300 refers to a planar or near-planar area on the heat sink 300 that directly contacts an external heat source (such as the bottom wall 110 of the inductor housing 100) for heat conduction. It has low surface roughness and good flatness error to ensure close contact with the external heat source. In some embodiments, silicone is coated between the heat dissipation surface 310 and the external heat source to ensure tight contact and improve heat conduction efficiency. In this embodiment, the power semiconductor devices in the power assembly are also mounted on the heat dissipation surface 310 of the heat sink 300, thus forming the heat sink 300 component in the converter. The heat dissipation surface 310 can be the machining reference surface of the radiator 300 body, or it can be a dedicated thermally conductive bonding area formed by die casting, machining, or surface treatment. Its material is preferably a high thermal conductivity aluminum alloy (such as A380 or 6063) or copper alloy, and it can be configured as an air-cooled finned substrate, a liquid-cooled channel panel, or a heat pipe evaporation end bearing surface, depending on the cooling method. In this embodiment, the radiator 300 is a liquid-cooled radiator 300, which has several liquid-cooled flow channels inside and can be connected to an external coolant circulation device through inlet and outlet nozzles. The coolant circulation device then exchanges heat through an external heat exchange device to reduce the coolant temperature.

[0048] The inductor assembly includes an inductor housing 100, a plurality of inductor bodies 200, and a plurality of heat-conducting components 400. The inductor housing 100 has a receiving chamber 101 for accommodating the inductor bodies 200, and the inductor bodies 200 are housed in the receiving chamber 101. In this embodiment, referring to... Figure 1 and Figure 2 The inductor housing 100 has a roughly rectangular shape when viewed from above, and it has length and width directions, that is... Figure 2 The inductor housing 100 forms a rectangular cavity 101 in terms of its front-to-back and left-to-right directions. The cavity 101 is rectangular in plan view, with its width roughly matching the width of the inductor body 200, and its length sufficient to accommodate multiple inductor bodies 200 arranged sequentially. When the inductor bodies 200 are housed within the cavity 101, they are arranged sequentially along a first direction, which is... Figure 2 The left and right directions are shown.

[0049] Reference Figure 1 The inductor body 200 includes an iron core 210, a coil 220, and a support 230.

[0050] Specifically, the iron core 210 includes a shaft core 212 and several side cores 211 arranged around the coil 220. The shaft core 212 is located at the center of the iron core 210, and its two ends extend out of the two ends of the coil 220. Each shaft core 212 is provided with four side cores 211. Two side cores 211 are attached to the outer peripheral surfaces of the left and right sides of the shaft core 212 in the front-back direction, and the other two side cores 211 are connected to the outer ends of the two side cores 211 in the left-right direction, forming a closed rectangular magnetic circuit structure. When multiple inductor bodies 200 are arranged sequentially in the front-back direction in the converter, two adjacent inductor bodies 200 share a side core 211 located between them, so as to reduce material usage, optimize spatial layout and enhance the overall magnetic circuit continuity. The core material 210 is a high-permeability soft magnetic alloy, preferably a silicon steel sheet laminated structure, an amorphous alloy strip wound structure, or a powder metallurgy iron-silicon-aluminum magnetic powder core. Its operating frequency range covers 10kHz to 200kHz, and its saturation magnetic flux density is not less than 1.2T, so as to adapt to the high-frequency and high-current operating conditions in the converter.

[0051] Coil 220 is a multi-layer flat winding made of copper wire, with the winding axis parallel to the first direction. The wire cross-section is rectangular or trapezoidal, and the number of turns is set between 10 and 50 turns according to the inductance requirement. The surface of the wire is coated with polyesterimide or polyamideimide insulating varnish with a heat resistance rating of 180℃ or higher to ensure stable electrical insulation performance at high temperatures. After winding, coil 220 has a rounded rectangular cross-section, and its four corners are rounded transition structures. The rounded part is the bending part 221 of coil 220, which is used to realize the turning of the wire from one layer to another to avoid stress concentration. The inner and outer diameters of coil 220 match the magnetic circuit profile of iron core 210, so that coil 220 is tightly wrapped around the core 212 and side core 211 of iron core 210.

[0052] The bracket 230 is an injection-molded engineering plastic part, located at both ends of the coil 220. It serves to fix the axial position of the coil 220, provide mechanical support, and achieve electrical insulation between the conductor of the coil 220 and the iron core 210 and the inductor housing 100. The main body of the bracket 230 has a ring-shaped structure, with one side surface abutting the end of the coil 220. A large through hole is provided in the middle along the front-back direction for the end of the shaft 212 in the iron core 210 to pass through. Two lugs are also provided on the top of the bracket 230, extending outwards relative to the inductor housing 100 along the front-back direction. The two ends of the coil 220 can be placed and fixed on these lugs for easy connection to external circuits. The material of the bracket 230 is selected with a temperature resistance ≥180℃ and a volume resistivity not less than 10 Ω·cm. 14 High-performance insulating engineering plastics with Ω·cm and dielectric strength greater than 20kV / mm, preferably polyamide-imide (PAI), liquid crystal polymer (LCP) or modified polyphenylene sulfide (PPS).

[0053] Reference Figure 6 and Figure 7 The inductor housing 100 has a bottom wall 110 for the inductor body 200 to sit on. The bottom wall 110 has a first surface 111 forming the cavity wall of the receiving chamber 101, and a second surface 112 opposite to the first surface 111. The first surface 111 and the second surface 112 are both planar so that the bottom wall 110 has a uniform wall thickness.

[0054] Specifically, the inductor housing 100 includes a bottom wall 110 and a side wall 130. The bottom wall 110 is located below and lies flat along the horizontal plane, while the side wall 130 is located above and extends vertically. The side wall 130 is arranged around the peripheral edge of the bottom wall 110, thereby forming the inductor housing 100 into a receiving chamber 101 with a top opening. The bottom wall 110 is die-cast from a high thermal conductivity aluminum alloy. In a preferred embodiment, the overall thickness of the bottom wall 110 is in the range of 1.5 mm to 3.0 mm, and the thickness of the bottom wall 110 remains uniform to ensure stable molten metal flow and the absence of shrinkage cavities or cold shut defects during the die-casting process. The upper surface of the bottom wall 110, which forms the bottom cavity wall of the receiving chamber 101, is the first surface 111, and the lower surface of the bottom wall 110, which is used to allow the inductor housing 100 to rest on the heat dissipation surface 310 of the heat sink 300, is the second surface 112. The first surface 111 and the second surface 112 define the thickness of the bottom wall 110 in the vertical direction, and the two are parallel planes, so that the bottom wall 110 has a consistent wall thickness.

[0055] Furthermore, referring to Figure 6In this embodiment, the inductor housing 100 has a plurality of heat-conducting protrusions 121 protruding from the inner surface of the bottom wall 110 of the accommodating chamber 101. The protrusion shape of the heat-conducting protrusions 121 is adapted to at least a portion of the bottom shape of the inductor body 200, so that the heat-conducting protrusions 121 contact the corresponding inductor body 200. The inner surface of the bottom wall 110 of the accommodating chamber 101 is the aforementioned first surface 111. These heat-conducting protrusions 121 form heat-conducting surfaces 122 adapted to the outer peripheral shape of the coil 220, so that the heat-conducting surfaces 122 can conformally contact the coil 220. Specifically, two heat-conducting protrusions 121 cooperate to form a heat-conducting module. The two heat-conducting protrusions 121 in the heat-conducting module are arranged along the second direction, and the two heat-conducting protrusions 121 are arranged opposite each other in the left-right direction. They have the same shape but the orientation of the heat-conducting surfaces 122 is opposite. Each heat-conducting protrusion 121 has its side facing the coil 220 machined into an arc-shaped heat-conducting surface 122. The arc shape and size of the heat-conducting surface 122 are adapted to the shape and size of the bend 221 in the outer periphery of the coil 220, so as to achieve conformal fitting between the heat-conducting surface 122 and the bend 221 in the outer periphery of the coil 220. The heat-conducting surfaces 122 of two heat-conducting protrusions 121 belonging to the same heat-conducting module are arranged opposite each other, and the heat-conducting module in the inductor housing 100 is integrally formed with the bottom wall 110 by die casting. The heat-conducting protrusions 121 can also effectively dissipate heat from the bottom of the inductor body 200. Moreover, compared with using a separate bottom heat-conducting block, this integrated structure reduces the number of components and assembly steps, simplifying the manufacturing process. Meanwhile, since the thermally conductive protrusion 121 is part of the inductor housing 100, there is no interfacial thermal resistance between the two. The path of heat transfer from the bottom of the inductor body 200 to the inductor housing 100 is more direct, and the heat conduction efficiency is higher.

[0056] In one embodiment, when the inductor housing 100 is integrally formed by die casting, the position of the thermally conductive protrusion 121 corresponding to the bottom wall 110 can be recessed on one side of the second surface 112 to ensure that the wall thickness of the inductor housing 100 is approximately the same at all locations. In this embodiment, the thermally conductive protrusion 121 is constructed as a structure divided into multiple thermally conductive walls by relief grooves. Specifically, the thermally conductive protrusion 121 is recessed along the vertical direction with the thermally conductive surface 122 as a reference to form a plurality of relief grooves spaced apart along the front-back direction. The bottom of the relief grooves in the vertical direction is flush with the first surface 111. The thermally conductive protrusion 121 is divided by the relief grooves to form a plurality of thermally conductive walls spaced apart along the first direction. The wall thickness of the thermally conductive walls is equivalent to that of the bottom wall 110. These relief grooves divide the heat-conducting protrusion 121 into several relatively independent heat-conducting walls. The thickness of the heat-conducting wall can be controlled between 0.8 and 1.5 times the thickness of the bottom wall 110, preferably 1.2 times. This thickness range ensures that heat is efficiently conducted from the coil 220 to the heat-conducting wall through the heat-conducting surface 122, and also ensures that the molten metal fills the mold cavity evenly without dead zones during die casting, avoiding casting defects such as porosity, shrinkage, or cold shuts. The thickness of the heat-conducting wall can be adjusted by adjusting the width of the relief groove in the front-to-back direction and the number of relief grooves.

[0057] Furthermore, each heat-conducting element 400 in this inductor assembly corresponds to an inductor body 200, used to assist in conducting heat from the top region of the coil 220 to the inductor housing 100. (See reference...) Figure 1 , Figure 2 and Figure 3 The heat-conducting component 400 is provided with a contact portion 410 that is adapted to at least a portion of the shape of the inductor body 200, and is correspondingly contacted and disposed on the inductor body 200 through the contact portion 410; the heat-conducting component 400 extends from the contact portion 410 along a second direction that is generally perpendicular to the first direction and is provided with at least one heat-conducting portion 420, the heat-conducting portion 420 contacting the inner wall of the inductor housing 100.

[0058] Specifically, refer to Figure 3The heat-conducting element 400 has a cross-shaped structure, including a contact portion 410 extending in the left-right direction and two heat-conducting portions 420 extending forward and backward respectively. The contact portion 410 of the heat-conducting element 400 is adapted to at least a portion of the outer peripheral wall of the coil 220 so that the heat-conducting element 400 contacts and is disposed on the coil 220. In this embodiment, the lower surface of the contact portion 410 of the heat-conducting element 400 is configured to conform to the outer contour of the top of the coil 220 in the inductor body 200, achieving a conformal fit to maximize contact with the upper surface of the coil 220. Specifically, the lower surface of the contact portion 410 includes a flat area located in the middle of the left-right direction and an arc-shaped area located at both ends of the left-right direction. Furthermore, in the overall structure of the contact portion 410, its upper surface is completely planar, only bending downwards at both ends of the left-right direction to form end structures that insert into the gap between the coil 220 and the two side cores 211 in the left-right direction. This end structure can be inserted into the gap between the coil 220 and the side core 211, avoiding interference with adjacent structures and increasing the overall structural strength and heat capacity of the heat conductor 400 by increasing the local thickness. It also ensures a flat upper surface for the inductor assembly, facilitating subsequent packaging or assembly operations. Specifically, the contact portion 410 of the heat conductor 400 is shaped and positioned to match the outer peripheral wall of the coil 220, which is the main heat source, directly placing the starting point of the heat conduction path at the location where heat generation is most concentrated. By matching the geometry of the contact portion 410 with the outer peripheral contour of the coil 220, a large-area, low-gap physical contact is formed, minimizing interfacial thermal resistance. This ensures that heat generated on the surface of the coil 220 is collected and efficiently transferred into the heat conductor 400 immediately, preventing ineffective diffusion and accumulation of heat to other low-temperature components of the inductor body 200 (such as the iron core 210). The contact portion 410 not only contacts the top side of the coil 220, but also extends in a direction perpendicular to the axial direction of the coil 220 to form contact with both sides of the coil 220 in the first direction, thus achieving multi-faceted coverage of the coil 220. This wraparound contact structure increases the effective area for heat collection compared to contact only at the top, further improving heat dissipation efficiency.

[0059] The heat-conducting component 400 has two heat-conducting parts 420, extending forward and backward respectively along the second direction. To avoid interference with structures such as the lead-out end of the coil 220 and the ear of the bracket 230, the two heat-conducting parts 420 are staggered in the first direction, ensuring that they do not interfere with the electrical connection structure or mechanical support structure on the inductor body 200 during assembly. Each heat-conducting part 420 extends from the contact part 410 and finally makes direct contact with the inner wall 130 of the inductor housing 100, thereby creating a low thermal resistance, high-efficiency lateral heat conduction path between the inductor body 200 and the housing. This path is as follows: coil 220, contact part 410, heat-conducting part 420, inductor housing 100, heat sink 300. Through this path, the heat generated in the top area of ​​the coil 220 can be quickly dissipated, effectively reducing the temperature of local hot spots, improving the uniformity of axial and lateral temperature distribution of the inductor body 200, and enhancing overall thermal stability.

[0060] The material of the heat-conducting component 400 is preferably a ceramic matrix composite material with high thermal conductivity and electrical insulation, such as aluminum nitride (AlN), beryllium oxide (BeO), or silicon carbide (SiC) based ceramics, with a thermal conductivity of not less than 120 W / (m·K) and a volume resistivity greater than 10 Ω·m. 12 The thermal conductivity is measured in Ω·cm to ensure efficient heat conduction under high temperature and high voltage conditions while reliably blocking leakage current between the coil 220 and the casing. In some embodiments, the heat-conducting component 400 may also be made of metal-based composite materials (such as aluminum silicon carbide SiC / Al), but an insulating coating must be added to its contact surface with the coil 220 to maintain electrical isolation. Thermally conductive ceramic materials possess extremely high thermal conductivity and excellent electrical insulation properties. High thermal conductivity is a prerequisite for ensuring extremely low thermal resistance in the constructed solid heat conduction path. Excellent electrical insulation properties ensure that the heat-conducting component 400, while acting as a thermal bridge, will not cause electrical short circuits under high voltage operating conditions. Thus, an efficient heat conduction path is constructed while ensuring electrical safety.

[0061] Furthermore, referring to Figure 3 , Figure 4 and Figure 5The end of the heat-conducting portion 420 is provided with an extension portion 421. This extension portion 421 extends outward from the contact area between the heat-conducting portion 420 and the inner wall of the inductor housing 100, and its extension profile matches the geometry of the inner wall of the inductor housing 100. In this embodiment, the heat-conducting element 400 is disposed on the top of the inductor body 200, its heat-conducting portion 420 rests against the upper surface of the side core 211, and the extension portion 421 is located in the gap between the side core 211 and the inner wall of the side wall 130 of the inductor housing 100. Specifically, the heat-conducting part 420 can be further divided into two parts: a connecting arm 422 and an extension part 421. The connecting arm 422 connects the contact part 410 and the extension part 421, and overlaps the top of the side core 211 to ensure that heat is smoothly transferred from the contact part 410 to the extension part 421. The extension part 421 is designed as a thin sheet structure, and its outline is consistent with the inner wall of the side wall 130 of the inductor housing 100, so that it can fully fit the inner surface of the side wall 130 to achieve a large-area thermal contact. By providing the extension part 421 on the heat-conducting part 420 of the heat-conducting component 400, and making the extension method of the extension part 421 the same as the inner wall of the inductor housing 100, the effective contact area between the heat-conducting component 400 and the inner wall of the inductor housing 100 is significantly increased. The increase in contact area can directly reduce the interfacial thermal resistance, increase the heat transfer flux per unit time, and thus improve the thermal conductivity. Furthermore, the thinner structure of the extension portion 421 effectively reduces the volume occupied by the heat-conducting element 400 between the inductor body 200 and the inner wall of the inductor housing 100, making it easier to install the heat-conducting element 400. The extension portion 421 is confined within the space between the side core 211 and the inner wall of the accommodating chamber 101, utilizing the natural gap formed between the side core 211 and the inner wall of the housing. By designing the extension portion 421 here, not only is full and reliable contact between the heat-conducting element 420 and the inner wall of the housing achieved, but no additional space is required or the main body size of the inductor body 200 is changed. This solves the core problem that when multiple inductors are arranged side by side, the heat-conducting element 400 cannot directly contact the inner wall of the housing due to the obstruction of the side core 211.

[0062] In another embodiment, the bottom wall 110 of the inductor housing 100 may not have the aforementioned heat-conducting protrusions 121, but instead has similarly structured bottom heat-conducting blocks. These bottom heat-conducting blocks are correspondingly disposed between the bottom of the inductor body 200 and the bottom wall 110 of the accommodating chamber 101, and are in contact with both. Furthermore, both the bottom heat-conducting blocks and the heat-conducting element 400 are made of the same or similar heat-conducting ceramic material. The bottom heat-conducting blocks and the top heat-conducting element 400 work together to form a three-dimensional heat dissipation structure that dissipates heat simultaneously from both the top and bottom of the inductor body 200. This arrangement not only reduces the overall average temperature of the inductor body 200 more quickly, but also improves the internal temperature gradient of the inductor body 200, making the internal temperature distribution more uniform and avoiding the problem of localized overheating of the inductor body 200.

[0063] Finally, after assembling the inductor assembly, a thermally conductive medium, such as conventional potting compound, can be injected into the accommodating chamber 101 of the inductor assembly. This not only further improves the thermal conductivity but also enhances the positional stability and overall structural strength of the inductor body 200.

[0064] This embodiment provides an inductor assembly that establishes an efficient solid-state heat conduction path between the inductor body 200 and the inductor housing 100 by setting a heat-conducting element 400 with a specific structure, thus improving the problem that the heat dissipation effect of the inductor coil 220 in the prior art cannot meet the requirements. In the prior art, in order to achieve a compact structure, multiple inductor bodies 200 are usually closely arranged in one direction within the same housing chamber 101 of the inductor housing 100. This layout results in the sides of the inductor body 200 located on the inside being blocked by adjacent inductor bodies 200, making it difficult for heat to be conducted laterally. At the same time, conventional heat dissipation methods rely on filling the housing chamber 101 with potting compound, using the potting compound to conduct heat from the inductor body 200 to the inductor housing 100. However, the thermal conductivity of potting compound is usually very low, which creates a significant thermal resistance between the heat source and the inductor housing 100. This causes a large amount of heat to accumulate inside the inductor body 200 and cannot be efficiently dissipated, which severely limits the power carrying capacity and long-term reliability of the inductor assembly.

[0065] The heat-conducting component 400 used in this embodiment has a contact portion 410 and a heat-conducting portion 420. The structural shape of the contact portion 410 of the heat-conducting component 400 is adapted to at least a portion of the shape of the inductor body 200, and the contact portion 410 is disposed in contact with the inductor body 200, so that the heat-conducting component 400 can make direct contact with the inductor body 200 with a large area and low thermal resistance, thereby efficiently collecting heat at the starting point of the heat conduction path. The heat-conducting portion 420 extends from the contact portion 410 along a second direction, spans the space between the inductor body 200 and the inner wall of the inductor housing 100, and contacts the inner wall of the inductor housing 100, thereby establishing a direct physical connection between the inductor body 200 and the inductor housing 100. Furthermore, through the structural design of the heat-conducting part 420, each inductor body 200 arranged in the inductor housing 100, whether located at both ends of the array or sandwiched in the middle, can establish the required heat conduction path without interference, thereby transferring heat laterally to the inductor housing 100. Compared to the structure that establishes heat conduction paths from both sides of the axial direction of the inductor body 200 through the heat-conducting element 400, in this solution, the heat-conducting part 420 is arranged along the axial direction of the inductor body 200. The heat-conducting part 420 does not need to cross other inductor bodies 200 to directly contact the inductor housing 100, allowing the heat of all inductor bodies 200 in the array to be quickly dissipated. Therefore, this solution can improve the problem of uneven heat dissipation caused by the arrangement, making the temperature distribution of the entire inductor assembly more balanced, significantly improving the overall heat dissipation performance of the assembly and its operational reliability under extreme conditions.

[0066] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this utility model, but does not constitute a limitation on the scope of protection of this utility model. Modifications, equivalent substitutions, or other improvements to the embodiments of this utility model or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this utility model or the foregoing embodiments, should all be included within the scope of protection of this utility model.

Claims

1. An inductor assembly, characterized in that it comprises: The inductor housing (100) has a receiving chamber (101); A plurality of inductor bodies (200), each of the inductor bodies (200) being arranged sequentially in the accommodating cavity (101) along a first direction; a plurality of heat-conducting elements (400), each heat-conducting element (400) having a contact portion (410) adapted to at least a portion of the shape of the inductor body (200), and correspondingly contacting one of the inductor bodies (200) through the contact portion (410); each heat-conducting element (400) having at least one heat-conducting portion (420) extending from the contact portion (410) along a second direction generally perpendicular to the first direction, the heat-conducting portion (420) contacting the inner wall of the inductor housing (100).

2. An inductor component as described in claim 1, characterized in that, The inductor body (200) includes an iron core (210) and a coil (220) wound on the iron core (210); the contact portion (410) of the heat-conducting element (400) is adapted to at least a portion of the outer peripheral wall of the coil (220) so that the heat-conducting element (400) is in contact with the coil (220).

3. An inductor component as described in claim 2, characterized in that, The heat-conducting part (420) of the heat-conducting component (400) is provided with an extension part (421); the extension part (421) is formed by extending from the part of the heat-conducting part (420) that contacts the inner wall of the inductor housing (100) in the same way as the inner wall of the inductor housing (100), so as to increase the contact area between the heat-conducting part (420) and the inductor housing (100).

4. An inductor assembly as described in claim 3, characterized in that, The iron core (210) includes a shaft core (212) passing through the coil (220) and a side core (211) surrounding the coil (220); the inductor housing (100) has an opening at the top of its accommodating chamber (101); the heat-conducting element (400) is disposed on the top of the inductor body (200), and its heat-conducting portion (420) rests on the side core (211), and the extension portion (421) is located between the side core (211) and the inner wall of the accommodating chamber (101).

5. An inductor component as described in claim 2, characterized in that, The contact portion (410) extends in a direction perpendicular to the axial direction of the coil (220) to contact at least a portion of the top side and both sides of the coil (220) in the first direction.

6. An inductor assembly as described in claim 2, characterized in that, It also includes several bottom heat-conducting blocks, which are correspondingly disposed between the bottom of an inductor body (200) and the bottom wall (110) of the accommodating chamber (101) and are in contact with both.

7. An inductor assembly as described in claim 2, characterized in that, The inductor housing (100) has a plurality of heat-conducting protrusions (121) protruding from the inner surface of the bottom wall (110) of the accommodating chamber (101); the protrusion shape of the heat-conducting protrusions (121) is adapted to at least part of the bottom shape of the inductor body (200) so that the heat-conducting protrusions (121) are in contact with the corresponding inductor body (200).

8. An inductor assembly as described in claim 6, characterized in that, The heat-conducting component (400) and the bottom heat-conducting block are made of heat-conducting ceramic material.

9. An inductive heat dissipation structure comprising a heat sink (300), characterized in that, It also includes an inductor assembly as described in any one of claims 1-8, wherein the bottom wall (110) of the inductor housing (100) is in close contact with the heat dissipation surface (310) of the heat sink (300).

10. A converter comprising a power component and a heat sink (300), wherein at least a portion of the power component is cooled by the heat sink (300), characterized in that, It also includes an inductor assembly as described in any one of claims 1-8, wherein the bottom wall (110) of the inductor housing (100) is in close contact with the heat dissipation surface (310) of the heat sink (300).

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