A double magnetic circuit high-power high-frequency inductor

Abstract

The utility model relates to a kind of high-power high-frequency inductance of double magnetic circuit in inductance field, including magnetic core, winding and shell, winding is divided into first winding and second winding, magnetic core is provided with middle column and two edge columns in, the both ends of copper foil conductor are formed with welding plane part, welding plane part is connected with integrated busbar lead-out end, integrated busbar lead-out end extends to the outside of shell, integrated busbar lead-out end includes insulating substrate and two conductive strips embedded in insulating substrate, by the both ends of copper foil conductor into the welding plane part, and with the conductive strip of integrated busbar lead-out end welding, realized the low resistance connection of large area plane, silica gel filling shell interior with high thermal conductivity, magnetic core, winding and internal connection point are completely wrapped, build from internal heating center to the efficient heat conduction channel of external shell, ensure that heat can be quickly, evenly radiated, effectively reduce the operating temperature rise of inductance.

Description

Technical Field

[0001] This utility model relates to the field of inductors, and in particular to a high-power high-frequency inductor with dual magnetic circuits. Background Technology

[0002] With the rapid development of power electronics technology towards higher frequencies and higher power densities, high-frequency inductors, as core energy storage and filtering components in switching power supplies, new energy inverters, and data center server power supplies, directly determine the efficiency, size, and reliability of the entire system. Increasing the operating frequency helps reduce the size of passive components, but it also poses extremely stringent challenges to the inductor's magnetic properties, low-loss characteristics, and thermal management capabilities at high frequencies.

[0003] Currently, traditional high-power high-frequency inductors have a series of inherent defects that are difficult to balance when pursuing high power density. The high current output terminals are usually connected by multi-strand wires or simple bolts, resulting in high connection resistance and poor mechanical stability. Under long-term vibration and thermal cycling, they are prone to becoming failure points. Heat accumulates inside the inductor, leading to excessive temperature rise, which seriously affects the performance stability and service life of the component. Utility Model Content

[0004] To overcome the shortcomings of existing technical solutions, this utility model provides a high-power high-frequency inductor with dual magnetic circuits, which can effectively solve the technical problems of not being able to guarantee the reliability of high-current connections and efficient heat dissipation.

[0005] The technical solution adopted by this utility model to solve its technical problem is:

[0006] A high-power high-frequency inductor with dual magnetic circuits includes a magnetic core, windings, and a housing. The windings are wound on the magnetic core and are divided into a first winding and a second winding. The magnetic core, the first winding, and the second winding are encapsulated within the housing. The magnetic core has a central post and two side posts, which are symmetrically arranged on both sides of the central post, forming a winding channel between the two side posts and the central post. The first winding and the second winding are wound on the two side posts, respectively. Both the first winding and the second winding are made of copper foil conductors, with welding planes formed at both ends of the copper foil conductors. The welding planes are connected to integrated busbar leads, which extend to the outside of the housing. The integrated busbar leads include an insulating substrate and two conductive strips embedded in the insulating substrate. The two ends of the conductive strips extend out of the insulating substrate, with one end welded to the welding plane of the winding and the other end extending out of the housing. The housing is filled with high thermal conductivity silicone, which encapsulates the magnetic core, the first winding, the second winding, and the conductive strips of the insulating substrate.

[0007] Furthermore, the cross-sections of the central column and the side columns are rectangular, with the cross-sectional area of ​​the central column being larger than that of the side columns, and the cross-sectional area of ​​the central column being 1.5-2.5 times that of the side columns.

[0008] Furthermore, the thickness of the copper foil conductor is 0.1-0.5 mm, and the surface of the copper foil conductor is covered with a high-temperature resistant polyimide film.

[0009] Furthermore, the housing is made of aluminum alloy, and the sides of the housing are provided with an array of heat dissipation fins.

[0010] Furthermore, the copper foil conductor is wound in a tight spiral flat winding manner on the side post, and an aramid paper insulation layer is provided between adjacent copper foil conductor layers.

[0011] Furthermore, the magnetic core is a one-piece sintered magnet made of manganese-zinc power ferrite.

[0012] Compared with existing technologies, the beneficial effects of this invention are as follows: By forming the two ends of the copper foil conductor into weldable flat surfaces and welding them with the conductive strips of the integrated busbar leads, a large-area planar low-resistance connection is achieved. This structure not only has low contact resistance and strong current carrying capacity, but also a firm mechanical connection and good shock resistance, completely solving the problems of easy loosening and overheating aging in traditional lead wire connection methods, and greatly improving the long-term reliability of the product. The high thermal conductivity silicone filling inside the shell completely encapsulates the magnetic core, windings, and internal connection points, creating an efficient heat conduction channel from the internal heating center to the outer shell, ensuring that heat can be dissipated quickly and evenly, effectively reducing the operating temperature rise of the inductor. At the same time, the potting structure and the aluminum alloy shell work together to give the product excellent moisture-proof, shock-proof, insulation, and mechanical protection properties, making it suitable for various harsh industrial environments. Attached Figure Description

[0013] Figure 1 This is a three-dimensional schematic diagram of the present invention;

[0014] Figure 2 This is an exploded view of the structure of this utility model;

[0015] Figure 3 This is a front sectional view of the present invention;

[0016] Figure 4 This is a right sectional view of the present invention;

[0017] Figure 5 This is a schematic diagram of the first winding, insulating substrate, and conductive strip in this utility model;

[0018] The numbers in the diagram are: 1-Magnetic core, 101-Center post, 102-Side post, 103-Winding channel, 2-Housing shell, 201-Shell body, 202-Shell cover, 203-Heat dissipation fins, 3-First winding, 4-Second winding, 5-Insulating substrate, 6-Conductive strip, 7-High thermal conductivity silicone. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] The following is combined with Figures 1-5 A detailed description of a high-power, high-frequency inductor with a dual magnetic circuit according to this invention is provided below:

[0021] A high-power high-frequency inductor with dual magnetic circuits includes a magnetic core 1, windings, and a housing 2. The windings are wound on the magnetic core 1 and are divided into a first winding 3 and a second winding 4. The magnetic core 1, the first winding 3, and the second winding 4 are encapsulated within the housing 2. The magnetic core 1 has a central post 101 and two side posts 102, which are symmetrically arranged on both sides of the central post 101. A winding channel 103 is formed between the two side posts 102 and the central post 101. The first winding 3 and the second winding 4 are respectively wound on the two side posts 102. Both the first winding 3 and the second winding 4 are made of copper foil conductors, and the two ends of the copper foil conductors have welding plane portions. By adopting a dual magnetic circuit structure consisting of a built-in central post 101 and symmetrical side posts 102, and having the two windings respectively wound on the side posts 102, a coupled inductor with symmetrical magnetic circuits and uniform magnetic flux distribution is formed. This design enables efficient utilization of the magnetic flux in core 1, especially the common center post 101, avoiding local saturation. This allows for greater power handling within the same core 1 volume, significantly improving the product's power density. The use of copper foil conductors instead of traditional enameled wire windings effectively suppresses the skin effect and proximity effect under high-frequency currents by utilizing the large surface area of ​​the copper foil. This greatly reduces the AC resistance of the windings, decreases copper losses, and improves the inductor's efficiency at high frequencies.

[0022] The welding plane is connected to an integrated busbar lead-out end, which extends to the outside of the housing 2. The integrated busbar lead-out end includes an insulating substrate 5 and two conductive strips 6 embedded in the insulating substrate 5. Both ends of the conductive strips 6 extend out of the insulating substrate 5, one end of which is welded to the welding plane of the winding, and the other end extends out of the outside of the housing 2. The housing 2 is filled with high thermal conductivity silicone 7, which wraps the magnetic core 1, the first winding 3, the second winding 4, and part of the conductive strips 6 of the insulating substrate 5.

[0023] By shaping the two ends of the copper foil conductor into weldable flat surfaces and welding them to the conductive strip 6 of the integrated busbar lead-out end, a large-area planar low-resistance connection is achieved. This structure not only has low contact resistance and strong current carrying capacity, but also a firm mechanical connection and good shock resistance, completely solving the problems of easy loosening and overheating aging of traditional lead wire connection methods, greatly improving the long-term reliability of the product. The high thermal conductivity silicone-filled shell 2 completely encapsulates the magnetic core 1, windings, and internal connection points, creating an efficient heat conduction channel from the internal heat generation center to the outer shell 2, ensuring that heat can be dissipated quickly and evenly, effectively reducing the inductor's operating temperature rise. At the same time, the potting structure and the aluminum alloy shell work together to give the product excellent moisture-proof, shock-proof, insulation, and mechanical protection properties, making it suitable for various harsh industrial environments.

[0024] The cross-sections of the central column 101 and the side columns 102 are rectangular. The cross-sectional area of ​​the central column 101 is larger than that of the side column 102, and the height of the central column 101 is equal to that of the side column 102. The width of the central column 101 is 1.5-2.5 times the width of the side column 102. The central column 101 has a larger cross-sectional area in the direction of magnetic flux flow, providing a low magnetic reluctance path for coupling magnetic flux, effectively preventing magnetic saturation, ensuring the stability of the inductance value under high current, and improving the utilization efficiency and power density of the magnetic core 1. The rectangular cross-section with equal height but unequal width makes the magnetic core 1 more structurally regular, facilitating winding and assembly.

[0025] The thickness of the copper foil conductor is 0.1mm, 0.2mm, 0.3mm, or 0.5mm. A high-temperature resistant polyimide film insulation layer is integrally coated on the surface of the copper foil conductor. This integrally coated polyimide film insulation layer replaces the traditional interlayer spacer, ensuring excellent electrical insulation strength and high-temperature resistance, withstanding temperatures above 200℃ for extended periods. Simultaneously, it reduces the space occupied by the insulation layer, further improving the compactness of the winding and heat dissipation efficiency.

[0026] The shell 2 is made of die-cast aluminum alloy and consists of a shell body 201 and a shell cover 202. On the outer surface of the shell body 201, there are multiple heat dissipation fins 203 that extend outward and are arranged vertically in parallel. This not only ensures structural strength but also establishes a strong passive heat dissipation capability, increases the effective heat dissipation surface area, and forms a natural air convection channel, which can efficiently guide internal heat to the ambient air and achieve a significant reduction in core temperature rise.

[0027] The magnetic core 1 is a monolithically sintered magnet made of manganese-zinc power ferrite with high saturation magnetic flux density, making the entire magnetic circuit a seamless, gapless whole. This minimizes magnetic reluctance and leakage, achieving high inductance while significantly reducing high-frequency eddy current losses and reducing heat generation in the magnetic core 1 at its source, which is the core foundation for achieving high-frequency, high-efficiency operation.

[0028] Furthermore, the copper foil conductor is wound in a tight spiral flat winding manner on the side post 102, making the winding structure compact and the magnetic field distribution uniform. An aramid paper insulation layer can be added between adjacent copper foil conductor layers. The aramid paper insulation layer not only enhances the insulation performance, but its high mechanical strength and creep resistance also provide solid support for the winding under thermal stress and mechanical vibration, effectively preventing the winding from loosening and deforming, and significantly improving the structural stability and lifespan of the product under harsh working conditions.

[0029] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A high-power high-frequency inductor with dual magnetic circuits, comprising a magnetic core, windings, and a housing, wherein the windings are wound on the magnetic core, the windings are divided into a first winding and a second winding, and the magnetic core, the first winding, and the second winding are encapsulated within the housing, characterized in that: The magnetic core contains a central post and two side posts, which are symmetrically arranged on both sides of the central post. A winding channel is formed between the two side posts and the central post. The first winding and the second winding are wound on the two side posts respectively. Both the first winding and the second winding are made of copper foil conductors. Welding planes are formed at both ends of the copper foil conductors. Integrated busbar leads are connected to the welding planes. The integrated busbar leads extend to the outside of the housing. The integrated busbar leads include an insulating substrate and two conductive strips embedded in the insulating substrate. Both ends of the conductive strips extend out of the insulating substrate. One end is welded to the welding plane of the winding, and the other end extends out of the outside of the housing. The housing is filled with high thermal conductivity silicone. The high thermal conductivity silicone wraps the magnetic core, the first winding, the second winding, and the conductive strips of the insulating substrate.

2. The high-power high-frequency inductor with dual magnetic circuits according to claim 1, characterized in that: The cross-sections of the central column and the side columns are rectangular, with the cross-sectional area of ​​the central column being larger than that of the side columns. The cross-sectional area of ​​the central column is 1.5 to 2.5 times that of the side columns.

3. The high-power high-frequency inductor with dual magnetic circuits according to claim 1, characterized in that: The copper foil conductor has a thickness of 0.1-0.5 mm, and its surface is covered with a high-temperature resistant polyimide film.

4. A high-power high-frequency inductor with dual magnetic circuits according to any one of claims 1-3, characterized in that: The housing is made of aluminum alloy, and the sides of the housing are provided with an array of heat dissipation fins.

5. A high-power high-frequency inductor with dual magnetic circuits according to any one of claims 1-3, characterized in that: The copper foil conductor is wound in a tight spiral flat winding manner on the side post, and an aramid paper insulation layer is provided between adjacent copper foil conductor layers.

6. A high-power high-frequency inductor with dual magnetic circuits according to any one of claims 1-3, characterized in that: The magnetic core is a one-piece sintered magnet made of manganese-zinc power ferrite.

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