A common differential mode inductor

Abstract

The utility model belongs to the technical field of magnetic component, specifically relates to a common mode inductance, including shell and inductance module, wherein, inductance module includes common mode inductance unit and difference mode inductance unit, difference mode inductance unit sets up along the length direction arrangement of common mode inductance unit, difference mode inductance unit includes a plurality of difference mode inductance subunit, and difference mode inductance subunit includes first magnetic core and fourth magnetic core, and the second magnetic core and third magnetic core of setting between first magnetic core and fourth magnetic core, first magnetic core and second magnetic core between, first magnetic core and third magnetic core between, fourth magnetic core and second magnetic core between, fourth magnetic core and third magnetic core between all are provided with ceramic sheet, common mode inductance unit includes fifth magnetic core and eighth magnetic core, and the sixth magnetic core and seventh magnetic core of setting between fifth magnetic core and eighth magnetic core, and the both ends of fifth magnetic core and eighth magnetic core, sixth magnetic core and seventh magnetic core are respectively covered with first polyaromatic paper and second polyaromatic paper.

Description

Technical Field

[0001] This utility model belongs to the field of magnetic components technology, specifically relating to a common-mode inductor. Background Technology

[0002] The statements in this section are merely background information related to this utility model and do not necessarily constitute prior art.

[0003] Differential mode inductors are crucial components in energy storage converters used to filter differential mode interference. Excessive temperature rise can lead to problems such as core saturation, insulation aging, and even system failure. Existing differential mode inductors consist of two E-type cores and winding coils wound around the core's central column. Each layer of winding coils, away from the core, is wrapped with insulating tape. However, existing differential mode inductors have the following problems: (1) The core loss is large. Traditional soft magnetic ferrite and metal alloys have significant hysteresis loss under high frequency and high temperature conditions and are prone to saturation, which cannot meet the working requirements under high temperature and high DC bias conditions. (2) Winding heat concentration, that is, winding on the same column, which leads to local high temperature in the winding and increases copper loss; (3) Low heat dissipation efficiency. Because it relies on natural heat dissipation and simple heat sinks, it cannot meet the heat dissipation requirements in high power density scenarios. Utility Model Content

[0004] To address the aforementioned issues, this invention proposes a common-mode inductor. By improving the core material, resetting the winding structure, and optimizing the heat dissipation structure, it solves the problem of excessive temperature rise in existing common-mode inductors and improves the coupling performance of the common-mode inductor.

[0005] According to some embodiments, the present invention provides a common-differential mode inductor, employing the following technical solution: A common-mode inductor includes a housing and an inductor module disposed on the housing. The inductor module includes a common-mode inductor unit and a differential-mode inductor unit disposed on one side of the common-mode inductor unit, the differential-mode inductor units being arranged along the length of the common-mode inductor unit. Each differential-mode inductor unit includes several structurally identical differential-mode inductor sub-units, each sub-unit including a first magnetic core and a fourth magnetic core with a U-shaped structure, and a second magnetic core and a third magnetic core with an I-shaped structure disposed between the first magnetic core and the fourth magnetic core. The first magnetic core and the second magnetic core... Ceramic sheets are disposed between the cores, between the first magnetic core and the third magnetic core, between the fourth magnetic core and the second magnetic core, and between the fourth magnetic core and the third magnetic core; the common mode inductor unit includes a fifth magnetic core and an eighth magnetic core with a U-shaped structure, and a sixth magnetic core and a seventh magnetic core with an I-shaped structure disposed between the fifth magnetic core and the eighth magnetic core. A first polyaramid paper is sleeved on one end of the fifth magnetic core and the eighth magnetic core, and on the sixth magnetic core. A second polyaramid paper is sleeved on the other end of the fifth magnetic core and the eighth magnetic core, and on the seventh magnetic core.

[0006] As a further technical limitation, a thermally conductive pad is provided between the housing and the inductor module.

[0007] As a further technical limitation, both the first and second polyaramid paper are provided with a second winding coil in a segmented structure, and the ends of the segments of the second winding coil are provided with an insulating plate in a ring structure.

[0008] Furthermore, the second winding coil adopts a two-layer winding coil structure, wherein the first layer winding coil is wrapped with high-temperature resistant tape for fixing the second winding coil.

[0009] Furthermore, the number of differential mode inductor sub-units is consistent with the number of segments in the second winding coil.

[0010] As a further technical limitation, a first insulating frame is provided on one side of the first magnetic core and the fourth magnetic core, as well as on the third magnetic core, and a second insulating frame is provided on the other side of the first magnetic core and the fourth magnetic core, as well as on the second magnetic core.

[0011] Furthermore, both the first insulating frame and the second insulating frame are provided with a first winding coil.

[0012] Furthermore, the first winding coil adopts a two-layer winding coil structure, wherein the first layer winding coil is wrapped with high-temperature resistant tape for fixing the first winding coil.

[0013] As a further technical limitation, the outer edge of the housing is provided with a hollow threaded hole.

[0014] As a further technical limitation, the common-mode inductor unit is connected to the differential-mode inductor subunit using a winding crossover method.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows: This invention replaces the E-type magnetic core with a combination of I-type and U-type magnetic cores, increasing the heat dissipation area of ​​the winding coil. Simultaneously, thermal pads are placed on the housing, ceramic sheets are segmented on the differential-mode inductor unit, and polyaramid paper is placed on the common-mode inductor unit. Furthermore, the first layer of the winding coil is not wrapped with tape, further improving heat dissipation and enhancing high-temperature resistance. The common-mode inductor unit is connected to the differential-mode inductor subunit using a winding crossover method, improving coupling. Attached Figure Description

[0016] The accompanying drawings, which form part of this specification, are used to provide a further understanding of this utility model. The illustrative embodiments of this utility model and their descriptions are used to explain this utility model and do not constitute an improper limitation of this utility model.

[0017] Figure 1 This is a schematic diagram of a common-mode inductor in an embodiment of this utility model; Figure 2 This is an exploded structural diagram of a common-mode inductor in an embodiment of this utility model; Figure 3 This is a schematic diagram of the winding structure of the common-mode inductor in an embodiment of this utility model; The components are as follows: 1. Housing; 2. Threaded hole; 3. First winding coil; 4. First magnetic core; 5. Second magnetic core; 6. Third magnetic core; 7. Fourth magnetic core; 8. Ceramic sheet; 9. First insulating frame; 10. Second insulating frame; 11. Second winding coil; 12. Fifth magnetic core; 13. Sixth magnetic core; 14. Seventh magnetic core; 15. Eighth magnetic core; 16. First polyaramid paper; 17. Second polyaramid paper; 18. Insulating plate; 19. First terminal; 20. Second terminal; 21. Third terminal; 22. Fourth terminal; 23. Fifth terminal; 26. Sixth terminal. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0019] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0020] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to the present invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0021] In this utility model, terms such as "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", "side", and "bottom" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to facilitate the description of the structural relationship between the various components or elements of this utility model and do not specifically refer to any component or element in this utility model. They should not be construed as limiting this utility model.

[0022] In this utility model, terms such as "fixed connection," "connected," and "joined" should be interpreted broadly, indicating a fixed connection, an integral connection, or a detachable connection; a direct connection or an indirect connection through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in this utility model can be determined according to the specific circumstances, and should not be construed as a limitation of this utility model.

[0023] Example This utility model embodiment introduces a common-mode inductor.

[0024] like Figure 1 and Figure 2 The diagram shows a common-mode inductor, including a housing 1 and an inductor module (not shown in the figure) disposed on the housing 1; wherein, the outer edge of the housing 1 is provided with a threaded hole 2; the inductor module includes a common-mode inductor unit (not shown in the figure) and a differential-mode inductor unit (not shown in the figure) disposed on one side of the common-mode inductor unit, the differential-mode inductor units are arranged along the length direction of the common-mode inductor unit, and the differential-mode inductor unit is a plurality of differential-mode inductor sub-units with the same structure.

[0025] The differential mode inductor subunit includes a first magnetic core 4, a second magnetic core 5, a third magnetic core 6, a fourth magnetic core 7, a first winding coil 3, a first insulating frame 9, a second insulating frame 10, and a ceramic sheet 8; specifically: like Figure 2As shown, the first magnetic core 4 and the fourth magnetic core 7 both adopt a U-shaped structure, and the second magnetic core 5 and the third magnetic core 6 both adopt an I-shaped structure; wherein, the two ends of the first magnetic core 4 and the fourth magnetic core 7 are connected by the second magnetic core 5 and the third magnetic core 6 respectively; and ceramic sheets 8 are provided between the first magnetic core 4 and the second magnetic core 5, between the first magnetic core 4 and the third magnetic core 6, between the fourth magnetic core 7 and the second magnetic core 5, and between the fourth magnetic core 7 and the third magnetic core 6.

[0026] It should be noted that the first magnetic core 4, the second magnetic core 5, the third magnetic core 6, and the fourth magnetic core 7 constitute a sealed structure.

[0027] A first insulating frame 9 is fitted on one side of the first magnetic core 4 and the fourth magnetic core 7, and on the third magnetic core 6; a second insulating frame 10 is fitted on the other side of the first magnetic core 4 and the fourth magnetic core 7, and on the second magnetic core 5; a first winding coil 3 is provided on both the first insulating frame 9 and the second insulating frame 10.

[0028] It should be noted that the ceramic sheet 8 is connected to the first magnetic core 4, the second magnetic core 5, the third magnetic core 6, and the fourth magnetic core 7 respectively by means of adhesive.

[0029] The common-mode inductor unit includes a second winding coil 11, a fifth magnetic core 12, a sixth magnetic core 13, a seventh magnetic core 14, an eighth magnetic core 15, a first polyaramid paper 16, a second polyaramid paper 17, and an insulating plate 18; specifically: like Figure 2 As shown, the fifth magnetic core 12 and the eighth magnetic core 15 both adopt a U-shaped structure, while the sixth magnetic core 13 and the seventh magnetic core 14 both adopt an I-shaped structure; the two ends of the fifth magnetic core 12 and the eighth magnetic core 15 are connected by the sixth magnetic core 13 and the seventh magnetic core 14, respectively.

[0030] It should be noted that the fifth magnetic core 12, the sixth magnetic core 13, the seventh magnetic core 14 and the eighth magnetic core 15 are connected by adhesive.

[0031] A first polyurethane paper 16 is fitted on one side of the fifth magnetic core 12 and the eighth magnetic core 15, and on the sixth magnetic core 13; a second polyurethane paper 17 is fitted on the other side of the fifth magnetic core 12 and the eighth magnetic core 15, and on the seventh magnetic core 14; a second winding coil 11 is provided on both the first polyurethane paper 16 and the second polyurethane paper 17.

[0032] It should be noted that the second winding coil 11 is arranged in a segmented structure, and each segment of the second winding coil 11 is provided with an annular insulating plate 18, wherein the insulating plate 18 provides a certain degree of isolation for adjacent second winding coils 11.

[0033] It should be noted that the number of differential mode inductor sub-units is consistent with the number of segments in the second winding coil 11.

[0034] The common-mode inductor unit and the differential-mode inductor unit are connected in a cross manner using the second winding coil 11, specifically: like Figure 3 As shown, several first winding coils 3 are arranged in sequence (i.e., 3a, 3b, 3c, 3d, 3e, and 3f), and second winding coils 11 are arranged in sequence (i.e., 11a, 11b, 11c, 11d, 11e, and 11f). The input terminals of 3a and 3b in the first winding coils 3 are connected to the first terminal 19, and their output terminals are connected to the input terminals of 11a and 11e in the second winding coils 11. The output terminals of 11a and 11e are connected to the fourth terminal 22. In the first winding coils 3... The input terminals 3c and 3d of the first winding coil 3 are connected to the second terminal 20, and their output terminals are integrated with the input terminals 11b and 11f of the second winding coil 11. The output terminals 11b and 11f of the second winding coil 11 are connected to the fifth terminal 23. The input terminals 3e and 3f of the first winding coil 3 are connected to the third terminal 21, and their output terminals are integrated with the input terminals 11c and 11d of the second winding coil 11. The output terminals 11c and 11d of the second winding coil 11 are connected to the sixth terminal 24. A fiberglass sleeve is fitted on the leads of the input terminals of the first winding coil 3 and the output terminals of the second winding coil 11 to provide heat insulation and enhance high-temperature resistance.

[0035] It should be noted that the first winding coil 3 uses enameled wire with two layers of coils. Tape is placed between the two adjacent layers of coils. High-temperature resistant tape is wrapped on both sides of the coil in the first layer to fix the wire ends and improve heat dissipation. The second winding coil 11 also has two layers of coils. High-temperature resistant tape is wrapped around the coil in the first layer to fix the coil of the second winding coil 11.

[0036] In this embodiment, the magnetic core is made of iron-based amorphous alloy with high saturation magnetic induction intensity (1.56T), and the enameled wire is of high temperature resistance grade EI / AIW and is wound symmetrically on both sides to enhance heat dissipation.

[0037] It should be noted that, in order to enhance the stability of the magnetic core in the differential mode inductor unit, the outer surface of the magnetic core in the differential mode inductor unit is wrapped with a steel strip.

[0038] In this embodiment, thermally conductive adhesive is potted between the inductor module and the housing 1 (an aluminum housing is used in this embodiment), and the potting height of the thermally conductive adhesive is 1 / 3 of the height of the inductor module; at the same time, a thermally conductive pad (not marked in the figure) is placed between the inductor module and the housing 1, which not only meets the safety withstand voltage level, but also plays a certain role in the bottom coil.

[0039] The end of the housing 1 is provided with a threaded hole 2, which can be fixed to the energy storage converter by bolts threaded into the threaded hole 2.

[0040] In this embodiment, the E-type magnetic core is replaced with a combination of I-type and U-type magnetic cores, which increases the heat dissipation area of ​​the winding coil. At the same time, a thermal pad is placed on the housing 1, ceramic sheets 8 are arranged in segments on the differential mode inductor unit, and polyaramid paper is arranged on the common mode inductor unit. In addition, the first layer of the winding coil is not wrapped with tape, which further improves the heat dissipation effect and enhances the high temperature resistance. The common mode inductor unit is connected to the differential mode inductor subunit by a winding cross method, which improves the coupling.

[0041] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

[0042] Although the specific embodiments of the present utility model have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present utility model. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solution of the present utility model are still within the scope of protection of the present utility model.

Claims

1. A common-mode inductor, characterized in that, The system includes a housing and an inductor module disposed on the housing. The inductor module includes a common-mode inductor unit and a differential-mode inductor unit disposed on one side of the common-mode inductor unit. The differential-mode inductor units are arranged along the length of the common-mode inductor unit. Each differential-mode inductor unit includes several structurally identical differential-mode inductor sub-units. Each differential-mode inductor sub-unit includes a first magnetic core and a fourth magnetic core with a U-shaped structure, and a second magnetic core and a third magnetic core with an I-shaped structure disposed between the first magnetic core and the fourth magnetic core. The first magnetic core and the second magnetic core are positioned... Ceramic sheets are disposed between the first magnetic core and the third magnetic core, between the fourth magnetic core and the second magnetic core, and between the fourth magnetic core and the third magnetic core. The common-mode inductor unit includes a fifth magnetic core and an eighth magnetic core with a U-shaped structure, and a sixth magnetic core and a seventh magnetic core with an I-shaped structure disposed between the fifth magnetic core and the eighth magnetic core. A first polyaramid paper is sleeved on one end of the fifth magnetic core and the eighth magnetic core, and on the sixth magnetic core. A second polyaramid paper is sleeved on the other end of the fifth magnetic core and the eighth magnetic core, and on the seventh magnetic core.

2. A common-mode inductor as described in claim 1, characterized in that, A thermally conductive pad is provided between the housing and the inductor module.

3. A common-mode inductor as described in claim 1, characterized in that, Both the first and second polyaramid paper are provided with a second winding coil in a segmented structure, and the ends of the segments of the second winding coil are provided with an insulating plate in a ring structure.

4. A common-mode inductor as described in claim 3, characterized in that, The second winding coil adopts a two-layer winding coil structure, wherein the first layer winding coil is wrapped with high-temperature resistant tape for fixing the second winding coil.

5. A common-mode inductor as described in claim 3, characterized in that, The number of differential mode inductor sub-units is consistent with the number of segments in the second winding coil.

6. A common-mode inductor as described in claim 1, characterized in that, A first insulating frame is fitted onto one side of the first magnetic core and the fourth magnetic core, as well as onto the third magnetic core; a second insulating frame is fitted onto the other side of the first magnetic core and the fourth magnetic core, as well as onto the second magnetic core.

7. A common-mode inductor as described in claim 6, characterized in that, Both the first insulating frame and the second insulating frame are provided with a first winding coil.

8. A common-mode inductor as described in claim 7, characterized in that, The first winding coil adopts a two-layer winding coil structure, wherein the first layer winding coil is wrapped with high-temperature resistant tape for fixing the first winding coil.

9. A common-mode inductor as described in claim 1, characterized in that, The outer edge of the housing is provided with a hollow threaded hole.

10. A common-mode inductor as described in claim 1, characterized in that, The common-mode inductor unit is connected to the differential-mode inductor subunit using a winding crossover method.

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