Power inductor applied to automobile electronic wireless charging module

Abstract

The utility model relates to power inductance field, concretely relates to a kind of power inductance applied to automobile electronic wireless charging module, comprising: core layer, for planar sheet structure;Polyester film layer, covers the top of core layer;Coil winding, for planar spiral coil, including first coil winding, second coil winding and third coil winding, wherein first coil winding and second coil winding are side by side pasted in the top of polyester film layer, and third coil winding is pasted in the top of first coil winding and second coil winding. Three layers of planar coil three-dimensional integration and planar magnetic core design are adopted, solve the problem of high frequency loss, structural reliability is insufficient and space utilization is low.

Description

Technical Field

[0001] This utility model relates to the field of power inductors, specifically to a power inductor used in automotive electronic wireless charging modules. Background Technology

[0002] With the development of the new energy vehicle industry, wireless charging technology has become an industry standard. Power inductors, as core components for magnetic field energy storage and conversion, play a crucial role in the transmitter's resonant compensation network and the receiver's energy conversion module, requiring them to meet specific system frequency band requirements for inductance, saturation current, and wide temperature range. Existing technologies face three major bottlenecks: First, in terms of high-frequency losses, traditional ferrite cores experience a decrease in permeability at high frequencies, resulting in a low Q value, significant core losses, and low system efficiency. Second, insufficient heat dissipation performance; the low thermal conductivity of ferrite leads to high temperature rise during full-load operation, exceeding relevant standards. Third, low space utilization; traditional structures are bulky, with insufficient core duty cycles, making them unsuitable for the flat layout requirements of automotive applications. Utility Model Content

[0003] To address the aforementioned issues, a power inductor for use in automotive electronic wireless charging modules is provided. It employs a three-layer planar coil integrated design and a planar magnetic core to solve the problems of high-frequency loss, insufficient structural reliability, and low space utilization.

[0004] To address the problems of existing technologies, this utility model provides a power inductor for use in automotive electronic wireless charging modules, comprising: The iron core layer has a planar sheet structure; A polyester film layer covers the top of the iron core layer; The coil winding is a planar helical coil, including a first coil winding, a second coil winding and a third coil winding, wherein the first coil winding and the second coil winding are attached side by side on top of the polyester film layer, and the third coil winding is attached on top of the first coil winding and the second coil winding. Preferably, the back of the core layer is provided with an adhesive backing layer.

[0005] Preferably, the first coil winding and the second coil winding are connected to the polyester film layer by epoxy resin adhesive.

[0006] Preferably, the third coil winding is connected to the first coil winding and the second coil winding via epoxy resin adhesive.

[0007] Preferably, it also includes a pin holder having slots for positioning the pins of all coil windings.

[0008] Preferably, the slot is provided with epoxy resin adhesive for fixing the pins of the coil winding.

[0009] Preferably, the nominal inductance of the power inductor is 12.5 μH, with an allowable deviation range of ±10%.

[0010] Preferably, the maximum DC resistance of the power inductor is 60mΩ.

[0011] Preferably, the operating temperature range of the power inductor is -40°C to 105°C.

[0012] The advantages of this utility model compared to the prior art are: Multi-winding three-dimensional integrated structure: It adopts a three-layer planar spiral coil (the first and second coil windings are arranged side by side, and the third coil winding is superimposed on top), combined with polyester film layer insulation isolation, to achieve efficient coupling and low interference transmission of magnetic field energy.

[0013] Composite insulation and fixing process: The coil and the substrate are bonded with epoxy resin, and the slot positioning design of the lead holder is used to improve the structural stability and vibration resistance.

[0014] Planar magnetic core design: Using a planar sheet-like iron core layer and an adhesive backing layer, the magnetic circuit distribution is optimized, the magnetic core loss is reduced, and the flat installation requirements of the vehicle wireless charging module are met. Attached Figure Description

[0015] Figure 1 This is a perspective view of a power inductor used in an automotive electronic wireless charging module according to this utility model.

[0016] Figure 2 This is a top view of a power inductor used in an automotive electronic wireless charging module according to this utility model.

[0017] Figure 3 This is a side view of a power inductor used in an automotive electronic wireless charging module according to this utility model.

[0018] Figure 4 This is a three-dimensional exploded view of a power inductor used in an automotive electronic wireless charging module according to this utility model.

[0019] The numbers in the diagram are: 1. Core layer; 2. Polyester film layer; 3. First coil winding; 4. Second coil winding; 5. Third coil winding; 6. Backing adhesive layer; 7. Epoxy resin adhesive; 8. Lead cage. Detailed Implementation

[0020] To further understand the features, technical means, and specific objectives and functions achieved by this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments.

[0021] Reference Figure 1 , Figure 2 and Figure 4 The power inductor shown is used in a wireless charging module for automotive electronics. It includes: a core layer 1, which is a planar sheet structure; a polyester film layer 2, covering the core layer 1; and a coil winding, which is a planar helical coil, including a first coil winding 3, a second coil winding 4, and a third coil winding 5. The first coil winding 3 and the second coil winding 4 are attached side-by-side above the polyester film layer 2, and the third coil winding 5 is attached above the first coil winding 3 and the second coil winding 4. An adhesive layer 6 is provided on the back of the core layer 1. (Refer to...) Figure 4 As shown, the first coil winding 3 and the second coil winding 4 are connected to the polyester film layer 2 via epoxy resin adhesive 7. The third coil winding 5 is connected to the first coil winding 3 and the second coil winding 4 via epoxy resin adhesive 7.

[0022] Multi-winding three-dimensional integrated structure: It adopts a three-layer planar spiral coil, combined with a polyester film layer 2 for insulation and isolation, to achieve efficient coupling and low-interference transmission of magnetic field energy.

[0023] Composite insulation and fixing process: The coil and the substrate (iron core layer 1) are bonded together with epoxy resin adhesive 7, and the slot positioning design of the pin holder 8 is used to improve the structural stability and vibration resistance.

[0024] Planar magnetic core design: Using a planar sheet-like iron core layer 1 and an adhesive backing layer 7, the magnetic circuit distribution is optimized, the magnetic core loss is reduced, and the flat installation requirements of the vehicle wireless charging module are met.

[0025] Reference Figure 2 , Figure 3 and Figure 4 As shown, it also includes a pin holder 8, which has slots for positioning the pins of all coil windings. Epoxy resin adhesive 7 is provided within the slots for securing the pins of the coil windings.

[0026] The performance parameters of the power inductor of this invention are as follows: Inductance (L1; L3): The nominal inductance is 12.5μH, with an allowable deviation range of ±10%, and the reference value is 12.5μH.

[0027] Inductance (L2): The nominal inductance is 11.5μH, with an allowable deviation range of ±10%, and the reference value is 11.5μH.

[0028] DC resistance (DCR1; DCR3): The maximum DC resistance is 60mΩ, and the reference value is 45mΩ.

[0029] DC resistance (DCR2): The maximum DC resistance is 60mΩ, and the reference value is 46mΩ.

[0030] Inductor turns: 12 turns.

[0031] Operating temperature (Ope.Temp): The operating temperature range is -40℃ to 105℃. Under operating conditions, the product temperature (ambient temperature + temperature rise) should not exceed 105℃.

[0032] Storage temperature (Store.Temp): The storage temperature range is -20℃ to 65℃. Store in unopened packaging.

[0033] Weight: 47.45g per product (for reference).

[0034] The above embodiments only illustrate one or more implementations of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the appended claims.

Claims

1. A power inductor used in automotive electronic wireless charging modules, characterized in that, include: The core layer (1) has a planar sheet structure; A polyester film layer (2) covers the top of the iron core layer (1); The coil winding is a planar helical coil, including a first coil winding (3), a second coil winding (4) and a third coil winding (5), wherein the first coil winding (3) and the second coil winding (4) are pasted side by side on the top of the polyester film layer (2), and the third coil winding (5) is pasted on the top of the first coil winding (3) and the second coil winding (4).

2. The power inductor for use in automotive electronic wireless charging modules according to claim 1, characterized in that, The back of the core layer (1) is provided with an adhesive layer (6).

3. The power inductor for use in automotive electronic wireless charging modules according to claim 1, characterized in that, The first coil winding (3) and the second coil winding (4) are connected to the polyester film layer (2) by epoxy resin adhesive (7).

4. The power inductor for use in automotive electronic wireless charging modules according to claim 1, characterized in that, The third coil winding (5) is connected to the first coil winding (3) and the second coil winding (4) through epoxy resin glue (7).

5. The power inductor for use in automotive electronic wireless charging modules according to any one of claims 1-4, characterized in that, It also includes a pin holder (8) having slots for positioning the pins of all coil windings.

6. The power inductor for use in automotive electronic wireless charging modules according to claim 5, characterized in that, The slot is provided with epoxy resin adhesive (7) for fixing the pins of the coil winding.

7. The power inductor for use in automotive electronic wireless charging modules according to claim 1, characterized in that, The nominal inductance of the power inductor is 12.5μH, with an allowable deviation range of ±10%.

8. The power inductor for use in automotive electronic wireless charging modules according to claim 1, characterized in that, The maximum DC resistance of the power inductor is 60mΩ.

9. The power inductor for use in automotive electronic wireless charging modules according to claim 1, characterized in that, The operating temperature range of the power inductor is -40°C to 105°C.

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