A toroidal inductor

Abstract

The utility model relates to technical field of electronic component discloses a kind of toroidal inductors, including toroidal core, symmetrical winding coil group, magnetic column enhancement module, heat dissipation shell and insulation protective layer;The toroidal core is integrated ferrite magnetic ring, its cross section presents trapezoidal structure;Symmetrical winding coil group is constituted by two groups of equal number of turns insulated wire, two groups of coils are symmetrical with the axis of toroidal core as axis respectively wound on half-ring surface, and spiral direction is opposite, and coil end is connected in series by silver-plated terminal;The magnetic column enhancement module includes at least two nanocrystalline magnetic column blocks, and the magnetic column block is connected in series with coil end after being encapsulated by epoxy resin, and magnetic column block axis is consistent with toroidal core tangent direction;The insulation protective layer is coated on the outer surface of coil and the outside of magnetic column block encapsulation layer;Through the coil design of two groups of reverse symmetrical winding, the heat conduction effect of combining silicon grease heat conduction layer, effectively avoid the performance attenuation caused by coil overheating, with good market application value.

Description

Technical Field

[0001] This utility model relates to the field of electronic component technology, and more particularly to a toroidal inductor. Background Technology

[0002] Currently, toroidal inductors are widely used in circuits for filtering, oscillation, and tuning due to their advantages such as good magnetic field closure and low leakage flux. In the prior art, toroidal inductors typically use a single coil wound on the surface of a magnetic core, which has problems such as insufficient withstand voltage and low high-frequency impedance, making it difficult to meet the requirements of output filter circuits for high-power amplifiers. At the same time, traditional toroidal inductors lack effective heat dissipation structures, and the coil heats up easily during long-term operation, which can lead to performance degradation. Furthermore, they are inconvenient to assemble and disassemble, making maintenance and replacement difficult.

[0003] Existing technology has flaws and needs improvement. Utility Model Content

[0004] To address the shortcomings of current technology, this invention provides a toroidal inductor.

[0005] This utility model provides a toroidal inductor, comprising a toroidal magnetic core, a symmetrically wound coil assembly, a magnetic pillar reinforcement module, a heat dissipation shell, and an insulating protective layer. The toroidal magnetic core is an integrated ferrite magnetic ring with a trapezoidal cross-section. The symmetrically wound coil assembly consists of two sets of insulated wires with equal turns, the two sets of coils being wound on the surface of a semi-ring with the axis of the toroidal magnetic core as the axis of symmetry, and the spiral directions being opposite. The ends of the coils are connected in series through silver-plated terminals. The magnetic pillar reinforcement module includes at least two nanocrystalline magnetic pillars, which are encapsulated with epoxy resin and connected in series with the ends of the coils. The axis of the magnetic pillars is aligned with the tangent direction of the toroidal magnetic core. The heat dissipation shell consists of an upper cover and a lower cover that are fastened together. The inner wall of the shell is provided with a silicone grease thermal conductive layer, and the side wall of the shell has honeycomb-shaped heat dissipation holes. The insulating protective layer is coated on the outer surface of the coils and the outer side of the magnetic pillar encapsulation layer.

[0006] Preferably, in the trapezoidal cross-section of the annular magnetic core, the upper base width is 8-12mm, the lower base width is 15-20mm, the height is 10-14mm, and the relative permeability of the magnetic core is ≥2000.

[0007] Preferably, the insulated wire is a polytetrafluoroethylene-coated copper wire with a diameter of 0.8-1.2 mm and an insulation layer thickness of ≥0.3 mm, and both sets of coils have 50-150 turns.

[0008] Preferably, the length of the nanocrystalline magnetic column is 10-15 mm, the diameter is 5-8 mm, and the thickness of the epoxy resin encapsulation layer on the surface of the magnetic column is 1-2 mm.

[0009] Preferably, the heat dissipation shell is made of aluminum alloy, and the upper cover and the lower cover are connected by a snap-fit ​​structure. The snap-fit ​​includes elastic blocks on both sides of the upper cover and corresponding slots on the lower cover.

[0010] Preferably, the diameter of the honeycomb heat dissipation holes is 2-3 mm, and the spacing between the holes is 5-8 mm.

[0011] Preferably, the insulating protective layer is made of polyimide coating, which is applied to the outer surface of the coil and the outer side of the magnetic column encapsulation layer, with a coating thickness of 0.2 mm.

[0012] Compared to the advantages of existing technologies, this utility model, through the design of two sets of reverse symmetrically wound coils, combined with the high-frequency impedance characteristics of nanocrystalline magnetic pillars, the combination design of aluminum alloy shell and honeycomb heat dissipation holes, and the thermal conduction effect of the silicone grease thermal layer, effectively avoids the performance degradation caused by coil overheating. The double-layer insulation protection of the outer surface of the coil and the magnetic pillars, combined with high-temperature resistant materials, ensures that the inductor works stably in high-temperature and high-pressure environments, reducing safety hazards. The snap-on shell structure can be disassembled and assembled without tools, which facilitates later maintenance and component replacement, improves the convenience of use, and has good market application value. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0014] Markings: 1. Toroidal magnetic core; 2. Symmetrically wound coil group; 3. Magnetic pillar reinforcement module; 4. Insulating protective layer; 5. Top cover. Detailed Implementation

[0015] It should be noted that the above-mentioned technical features can be combined with each other to form various embodiments not listed above, all of which are considered to be within the scope of this utility model specification; and, for those skilled in the art, improvements or modifications can be made based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims of this utility model.

[0016] To facilitate understanding of this utility model, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. The accompanying drawings show preferred embodiments of this utility model. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0017] It should be noted that when a component is described as being "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is described as being "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this specification are for illustrative purposes only.

[0018] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention.

[0019] The present invention will now be described in detail with reference to the accompanying drawings.

[0020] like Figure 1 The diagram shows a toroidal inductor comprising a toroidal magnetic core 1, a symmetrically wound coil group 2, a magnetic pillar reinforcement module 3, a heat dissipation shell, and an insulating protective layer 4. The toroidal magnetic core 1 is an integrated ferrite magnetic ring with a trapezoidal cross-section. The symmetrically wound coil group 2 consists of two sets of insulated wires with equal turns. The two sets of coils are wound on the surface of a semi-ring with the axis of the toroidal magnetic core 1 as the axis of symmetry, and the spiral directions are opposite. The ends of the coils are connected in series through silver-plated terminals. The magnetic pillar reinforcement module 3 includes at least two nanocrystalline magnetic pillars. The magnetic pillars are encapsulated with epoxy resin and connected in series with the ends of the coils. The axis of the magnetic pillars is aligned with the tangent direction of the toroidal magnetic core 1. The heat dissipation shell consists of an upper cover and a lower cover that are fastened together. The inner wall of the shell is provided with a silicone grease thermal conductive layer, and the side wall of the shell has honeycomb-shaped heat dissipation holes. The insulating protective layer 4 is coated on the outer surface of the coils and the outer side of the magnetic pillar encapsulation layer.

[0021] It should be noted that the toroidal inductor of this utility model includes a toroidal magnetic core 1, a symmetrically wound coil group 2, a magnetic pillar reinforcement module 3, a heat dissipation shell and an insulating protective layer 4. The toroidal core 1 features a trapezoidal cross-section design to enhance magnetic field concentration. Two sets of reverse-symmetrically wound coils are connected in series via silver-plated terminals, working in conjunction with nanocrystalline magnetic pillars to improve withstand voltage and high-frequency impedance. An aluminum alloy heat sink housing combined with honeycomb heat dissipation holes and a silicone grease thermal conductive layer achieves efficient heat dissipation. The snap-on housing structure facilitates assembly and maintenance, while the all-around insulation protection layer 4 ensures safety during use. Through the design of two sets of reverse-symmetrically wound coils, combined with the high-frequency impedance characteristics of the nanocrystalline magnetic pillars, the inductor's withstand voltage is increased to over 5kV, far exceeding the 2-3kV of traditional products, meeting the needs of high-power circuits. The synergistic effect of the ferrite toroidal core 1 and the nanocrystalline magnetic pillars increases the inductor's impedance by over 50% in the 1MHz-100MHz frequency band, resulting in a more significant filtering effect. The snap-on housing structure allows for tool-free disassembly and assembly, facilitating later maintenance and component replacement, improving ease of use. The double-layer insulation protection on the outer surface of the coils and the magnetic pillars, combined with high-temperature resistant materials, ensures stable operation of the inductor under high temperature and high pressure environments, reducing safety hazards.

[0022] Furthermore, the first and second coils of the symmetrically wound coil group 2 are both made of PTFE-coated copper wire with a diameter of 1.0 mm and an insulation layer thickness of 0.3 mm. Each coil group has 100 turns and is wound in opposite directions with the axis of the toroidal magnetic core 1 as the axis of symmetry. The ends of the coils are connected in series through silver-plated terminals.

[0023] Preferably, in the trapezoidal cross-section of the annular magnetic core 1, the upper base width is 8-12mm, the lower base width is 15-20mm, the height is 10-14mm, and the relative permeability of the magnetic core is ≥2000.

[0024] It should be noted that the synergistic effect of the ferrite toroidal core 1 and the nanocrystalline magnetic cylinder increases the impedance of the inductor by more than 50% in the 1MHz-100MHz frequency band, resulting in a more significant filtering effect.

[0025] Preferably, the insulated wire is a polytetrafluoroethylene-coated copper wire with a diameter of 0.8-1.2 mm and an insulation layer thickness of ≥0.3 mm, and both sets of coils have 50-150 turns.

[0026] It should be noted that the top of the insulated wire is provided with a top cover 5, that is, the top of the ring inductor is fixed with a top cover 5. The top cover 5 is a flat surface, which allows the robot arm to contact the upper side of the top cover 5, making it convenient for the robot arm to pick up the ring inductor.

[0027] Preferably, the length of the nanocrystalline magnetic column is 10-15 mm, the diameter is 5-8 mm, and the thickness of the epoxy resin encapsulation layer on the surface of the magnetic column is 1-2 mm.

[0028] It should be noted that the synergistic effect of the ferrite toroidal core 1 and the nanocrystalline magnetic cylinder increases the impedance of the inductor by more than 50% in the 1MHz-100MHz frequency band, resulting in a more significant filtering effect.

[0029] Furthermore, the magnetic pillar enhancement module 3 includes two nanocrystalline magnetic pillars, each with a length of 12mm and a diameter of 6mm, and a 1.5mm thick epoxy resin encapsulation layer on its surface. The two magnetic pillars are connected in series with the two ends of the coil group, and the axis of the magnetic pillars is consistent with the tangential direction of the toroidal magnetic core 1.

[0030] Preferably, the heat dissipation shell is made of aluminum alloy, and the upper cover and the lower cover are connected by a snap-fit ​​structure. The snap-fit ​​includes elastic blocks on both sides of the upper cover and corresponding slots on the lower cover.

[0031] It should be noted that the overall thickness of the casing is 3-5mm. The combination of the aluminum alloy casing and the honeycomb heat dissipation holes, along with the thermal conductivity of the silicone grease layer, reduces the inductor's operating temperature by 30%-40%, effectively preventing performance degradation caused by coil overheating.

[0032] Preferably, the diameter of the honeycomb heat dissipation holes is 2-3 mm, and the spacing between the holes is 5-8 mm.

[0033] It should be noted that the total area of ​​the heat dissipation holes accounts for 30%-40% of the area of ​​the side wall of the casing.

[0034] Preferably, the insulating protective layer 4 is made of polyimide coating, which is applied to the outer surface of the coil and the outer side of the magnetic column encapsulation layer, with a coating thickness of 0.2 mm.

[0035] Furthermore, during assembly, the two sets of coils are first wound symmetrically in opposite directions on the surface of the toroidal core 1, silver-plated terminals are soldered and connected in series with the magnetic pillar reinforcement module 3, and then an insulating protective layer 4 is coated on the outer surface of the coil. After the coating is cured, the whole unit is installed into the heat dissipation shell, and the upper and lower covers are fixed by clips to complete the assembly. The toroidal inductor of this embodiment has a withstand voltage of up to 6kV, an impedance of 800Ω in the 10MHz frequency band, and a temperature of no more than 65℃ after 2 hours of continuous operation, which meets the requirements of the output filter circuit of the high-power amplifier.

[0036] It should be noted that the above-mentioned technical features can be combined with each other to form various embodiments not listed above, all of which are considered to be within the scope of this utility model specification; and, for those skilled in the art, improvements or modifications can be made based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims of this utility model.

Claims

1. A toroidal inductor, characterized in that, The device comprises a toroidal magnetic core, a symmetrically wound coil assembly, a magnetic pillar reinforcement module, a heat dissipation shell, and an insulating protective layer. The toroidal magnetic core is an integrated ferrite magnetic ring with a trapezoidal cross-section. The symmetrically wound coil assembly consists of two sets of insulated wires with equal turns. The two sets of coils are wound on the surface of a semi-ring with the axis of the toroidal magnetic core as the axis of symmetry, and the spiral directions are opposite. The ends of the coils are connected in series through silver-plated terminals. The magnetic pillar reinforcement module includes at least two nanocrystalline magnetic pillars. The magnetic pillars are encapsulated with epoxy resin and connected in series with the ends of the coils. The axis of the magnetic pillars is aligned with the tangent direction of the toroidal magnetic core. The heat dissipation shell consists of an upper cover and a lower cover that are fastened together. The inner wall of the shell is provided with a thermally conductive silicone grease layer, and the side wall of the shell has honeycomb-shaped heat dissipation holes. The insulating protective layer is coated on the outer surface of the coils and the outer side of the magnetic pillar encapsulation layer.

2. A toroidal inductor according to claim 1, characterized in that, The trapezoidal cross-section of the toroidal magnetic core has an upper base width of 8-12mm, a lower base width of 15-20mm, a height of 10-14mm, and a relative permeability of ≥2000.

3. A toroidal inductor according to claim 1, characterized in that, The insulated conductor is a polytetrafluoroethylene-coated copper wire with a diameter of 0.8-1.2 mm and an insulation layer thickness of ≥0.3 mm. Both sets of coils have 50-150 turns.

4. A toroidal inductor according to claim 1, characterized in that, The nanocrystalline magnetic pillar has a length of 10-15mm, a diameter of 5-8mm, and an epoxy resin encapsulation layer on its surface with a thickness of 1-2mm.

5. A toroidal inductor according to claim 1, characterized in that, The heat dissipation shell is made of aluminum alloy. The upper cover and the lower cover are connected by a snap-fit ​​structure. The snap-fit ​​includes elastic blocks on both sides of the upper cover and corresponding slots on the lower cover.

6. A toroidal inductor according to claim 1, characterized in that, The honeycomb-shaped heat dissipation holes have a diameter of 2-3 mm and a spacing of 5-8 mm.

7. A toroidal inductor according to claim 1, characterized in that, The insulating protective layer is made of polyimide coating, which is applied to the outer surface of the coil and the outer side of the magnetic column encapsulation layer, with a coating thickness of 0.2 mm.

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