Combined high-power inductor

Abstract

The utility model discloses a combined high -power inductance, include: base, the magnetic core group is installed on the base, the magnetic core group includes two split magnetic core of opposite setting to constitute closed magnetic circuit, at least one flat vertical winding type coil, and set between the base with the magnetic core group, the flat vertical winding type coil around the split magnetic core's cylinder portion setting, and its lead end passes the base and leads out outward, insulating component, the insulating component includes the tubular insulating bushing of setting between the split magnetic core's cylinder with the flat vertical winding type coil, and the insulating baffle of setting between the end surface of flat vertical winding type coil with the yoke portion of split magnetic core. Compared with prior art, the inductance provided by the utility model has the advantages of simple inductance winding process, high production efficiency, small product volume and high product reliability.

Description

Technical Field

[0001] This utility model relates to the field of electronic components technology, specifically a combined high-power inductor. Background Technology

[0002] Inductors are key energy storage and filtering components in power electronic devices such as switching power supplies and inverters. With the increasing demands for power density and efficiency in applications such as electric vehicles and data centers, the need for high-power, miniaturized, and highly reliable inductors is becoming increasingly urgent.

[0003] Traditional high-power inductors are mostly wound with toroidal magnetic cores. While this structure offers a closed magnetic circuit and high efficiency, the winding process is complex: the wires must be repeatedly passed through the inner holes of the magnetic core manually or with the aid of a threading device, resulting in low production efficiency and difficulty in automation. To facilitate winding, the window size (inner diameter) of the toroidal magnetic core is usually designed to be relatively large, which directly leads to an increase in the overall size of the inductor, contradicting the current trend of miniaturization. Furthermore, the complex winding process can easily damage the enameled wire, introducing potential quality issues, and multiple layers of tightly wound wire increase the AC resistance and proximity effect losses of the coil, leading to severe heat generation.

[0004] Another common solution is to use composite magnetic cores such as EE and EI. Although the winding can be completed on the skeleton, the skeleton itself occupies window space, and the assembly process of multiple parts is complicated. Mechanical stability depends on adhesive bonding, and reliability is challenged in vibration environments such as vehicle-mounted environments.

[0005] Therefore, existing technologies suffer from problems such as difficult winding of inductor products, low production efficiency, high coil resistance, and excessively large overall size due to reserved winding space. The market urgently needs a new inductor structure that can carry large currents, is simple in structure, easy to manufacture, compact in size, and highly reliable. Utility Model Content

[0006] The purpose of this invention is to provide a combined high-power inductor to solve the technical problems of complex winding process, low production efficiency, large product size and insufficient product reliability in the existing inductor technology.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A combined high-power inductor, comprising:

[0009] Base;

[0010] A magnetic core assembly, which is mounted on the base, the magnetic core assembly comprising two separate magnetic cores arranged opposite each other to form a closed magnetic circuit;

[0011] At least one flat, vertically wound coil is disposed between the base and the magnetic core assembly. The flat, vertically wound coil is arranged around the cylindrical portion of the split magnetic core, and its lead end extends outward through the base.

[0012] An insulating assembly, the insulating assembly comprising a cylindrical insulating bushing disposed between the column of the split magnetic core and the flat vertically wound coil, and an insulating partition disposed between the end face of the flat vertically wound coil and the yoke of the split magnetic core;

[0013] The separate magnetic core and the flat vertical winding coil are separable independent components, but are combined into one unit through assembly.

[0014] Preferably, the split magnetic core is a UFY type magnetic core, each of the split magnetic cores includes an L-shaped yoke and a column extending horizontally from one end of the yoke. The columns of two split magnetic cores are arranged opposite to each other, and their yokes together constitute the main frame of the closed magnetic circuit.

[0015] Preferably, the material of the split magnetic core is a metal magnetic powder core or a high-permeability ferrite; when a metal magnetic powder core is used, it has a distributed air gap inside; when a high-permeability ferrite is used, it is used to form a high-inductance common-mode inductor.

[0016] Preferably, the flat vertically wound coil is formed by vertically winding a flat copper wire with a rectangular cross-section along its wide side, and the long side of the cross-section of the wound portion is parallel to the cylindrical axis of the split magnetic core.

[0017] Preferably, it further includes a core fixing clamp, which is disposed on the outside of the assembled core assembly and is used to provide a clamping force to the two separate cores to make their mating surfaces fit tightly together.

[0018] Preferably, the base is provided with pin holes for the lead ends of the flat vertically wound coil to pass through, and the part of the lead end that passes through the pin holes forms a solder pin for direct soldering to the circuit board.

[0019] Preferably, the mating surfaces of the two separate magnetic cores are bonded together with epoxy resin adhesive.

[0020] Preferably, at least two flat vertically wound coils are provided, and the at least two flat vertically wound coils are arranged side by side. An insulating partition is provided between two adjacent flat vertically wound coils, and the lead ends of each flat vertically wound coil are led out from the base in parallel for use in parallel or series connection in a multiphase circuit.

[0021] Preferably, the insulating bushing is made of NOMEX insulating sheet.

[0022] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0023] 1) Simplified process and improved production efficiency: The core improvement of this invention lies in decoupling the "winding" and the "magnetic core". The flat, vertically wound coil can be completely separated from the magnetic core, achieving high-speed, high-consistency automated winding (vertical winding) on ​​a dedicated fixture; subsequently, the prefabricated flat, vertically wound coil is quickly assembled with the separate UFY magnetic core. This completely eliminates the traditional toroidal magnetic core threading or complex skeleton winding process, increasing production efficiency several times over, and ensuring good product consistency and stable quality.

[0024] 2) Significantly reduced product size and increased power density: Due to the use of prefabricated vertically wound coils, there is no need to reserve space for manual operation on the magnetic core; the cylinder diameter of the UFY magnetic core can be designed to be only slightly smaller than the inner diameter of the coil, maximizing the utilization of the magnetic core window; simultaneously, the flat vertically wound coil itself has a smaller winding thickness for the same cross-sectional area compared to traditional round wire windings, further compressing the axial space. This compact design allows this invention to reduce its size compared to traditional toroidal inductors at the same current rating, perfectly meeting the requirements for high-power miniaturization.

[0025] 3) Optimized electrical performance and reduced losses and temperature rise: First, the use of flat copper wire results in lower DC resistance under high current; second, the "vertical winding" method makes the long side of the conductor cross-section parallel to the magnetic lines of force, effectively reducing eddy current losses at high frequencies; more importantly, when a metal magnetic powder core is used, its internal distributed air gap avoids the huge magnetic line distortion and local overheating problems at the concentrated air gap of traditional ferrite cores, resulting in a more uniform distribution of core losses, better heat dissipation, and a significant reduction in overall temperature rise.

[0026] 4) Enhanced mechanical and connection reliability: The dual fixation of the magnetic core with a core clamp and epoxy resin ensures the structural integrity of the magnetic core assembly under severe vibration. The lead wires are directly led out from the base and soldered, forming robust pin-type pins. This eliminates the vulnerability of traditional inductor flying wire soldering or conversion through additional terminals, significantly enhancing the pins' resistance to vibration and bending, and improving the long-term reliability of the entire device in harsh environments such as automotive applications. Attached Figure Description

[0027] Figure 1 This is one of the three-dimensional structural schematic diagrams of the inductor of this utility model;

[0028] Figure 2 for Figure 1 A schematic diagram of the exploded structure of an inductor;

[0029] Figure 3 This is the second three-dimensional structural schematic diagram of the inductor of this utility model;

[0030] Figure 4 for Figure 3 A schematic diagram of the exploded structure of an inductor.

[0031] In the diagram: 1. Base; 2. Magnetic core assembly; 21. Split magnetic core; 22. Magnetic core fixing clamp; 3. Flat vertical winding coil; 4. Insulation assembly; 41. Insulation bushing; 42. Insulation partition. Detailed Implementation

[0032] 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.

[0033] like Figures 1-4 As shown, the present invention provides a combined high-power inductor, which mainly consists of a base 1, a magnetic core assembly 2, a flat vertically wound coil 3, and an insulation component 4.

[0034] The base 1 is typically injection molded from high-temperature resistant, high-strength engineering plastics (such as PBT, nylon, etc.). Its bottom is designed with multiple pin holes, the size and position of which precisely match the coil lead ends. The upper surface of the base 1 may also be provided with positioning posts or grooves for preliminary positioning and limiting of the coil 3 and magnetic core assembly 2 during assembly, ensuring assembly accuracy.

[0035] The magnetic core assembly 2 is the core of the inductor's magnetic circuit. It is composed of two identical split magnetic cores 21 joined together. In this embodiment, the split magnetic cores 21 are preferably of a UFY type structure, with each core containing an L-shaped yoke and a cylindrical column extending horizontally from one end of the yoke. When the two magnetic cores are placed opposite each other, their columns are coaxially aligned, while their yokes are located on the upper side, forming a closed rectangular magnetic circuit. This split design is key to achieving coil pre-assembly. The magnetic core material can be selected according to the application scenario: when pursuing high saturation flux density and low high-frequency loss, a metal magnetic powder core (such as an iron-silicon-aluminum powder core) is selected, whose numerous tiny insulating particles naturally form a distributed air gap, eliminating the need for subsequent air gap grinding and providing uniform heat dissipation; when used to form a common-mode inductor requiring extremely high initial permeability, a high-permeability manganese-zinc ferrite can be selected. High-performance epoxy resin is coated on the splicing surface of the two split magnetic cores 21 for bonding and fixing and providing a certain stress buffer. To further enhance reliability in vibration environments, a core retaining clip 22 is also fitted onto the outside of the core assembly 2. This retaining clip 22 is typically made of stainless steel sheet with good elasticity and strength through stamping and bending. The continuous clamping force it generates can effectively prevent gaps from forming in the core after the adhesive layer ages or is heated.

[0036] The flat, vertically wound coil 3 is another core innovation of this invention. It is pre-wound from flat copper wire with a rectangular cross-section on a special mold. During winding, the copper wire is wound with its wider side upright (vertical winding). This pre-made coil is a completely independent component. Its inner diameter fits tightly with the outer diameter of the cylindrical part of the split magnetic core 21. The lead ends of the coil are pre-reserved and shaped to a specific angle and spacing during coil forming so that they can accurately pass through the pin holes of the base 1. After passing through, the enamel layer of the lead ends is removed and soldered to form pins that can be directly inserted into the through holes of the circuit board and wave soldered. This direct connection method eliminates the need for additional solder wires or copper terminals, reducing connection points and potential failure rates.

[0037] The insulation component 4 is used to ensure electrical safety between the coil and the magnetic core. It includes a cylindrical insulating bushing 41 that fits over the magnetic core cylinder. The bushing is preferably made of NOMEX insulating sheet and is used to isolate the inner wall of the coil from the magnetic core. In addition, an insulating partition 42, usually made of epoxy board, is placed between the two end faces of the flat vertically wound coil 3 and the yoke of the magnetic core to prevent creepage between the coil end faces and the magnetic core.

[0038] The number of flat, vertically wound coils 3 can be one (e.g., Figure 2 (As shown), it can also be a combination of multiple parallel elements (such as...) Figure 4 As shown), when it is a combination of multiple coils in parallel, an insulating partition 42 is placed between two adjacent coils.

[0039] Compared with existing technologies, the inductor of this invention has the following advantages:

[0040] First, by using prefabricated flat vertically wound coils and separate magnetic cores for assembly, the winding process is completely simplified, achieving high efficiency and automation in production and improving product consistency.

[0041] Secondly, this structure avoids the excessive window space required for traditional toroidal core winding, and with the compact core design, it significantly reduces the overall volume of the inductor and improves the power density.

[0042] In addition, the flat copper wire vertical winding method reduces DC resistance and eddy current loss. Combined with the distributed air gap design of the split magnetic core (such as metal magnetic powder core), it effectively reduces the overall temperature rise and improves electrical performance.

[0043] Finally, the dual fixation of the magnetic core clamp and epoxy resin adhesive, along with the robust connection of the lead end direct solder base, greatly enhances the mechanical reliability and long-term stability of the inductor under harsh environments such as vibration.

[0044] The assembly and working process of this utility model is as follows:

[0045] 1) Component prefabrication: The base 1, the split magnetic core 21, the prefabricated flat vertical winding coil 3, the insulating bushing 41 and the partition 42, and the magnetic core fixing clamp 22 are manufactured separately.

[0046] 2) Coil Installation: Insert the insulating bushing 41 into the magnetic core cylinder. Insert the pre-made flat, vertically wound coil 3, starting from its lead end downwards, into the cylinder (already fitted with a bushing) of one of the separate magnetic cores 21. Align the coil's lead end with and insert it into the pin hole of the base 1. At this time, the positioning structure of the base 1 prevents the coil from rotating or shifting.

[0047] 3) Core Assembly: An insulating bushing 41 is fitted onto the cylinder of another separate magnetic core 21, and epoxy resin is applied to its mating surface opposite the first magnetic core. Then, this magnetic core is aligned with the first magnetic core, the two cylinders are coaxially joined, and pressed downwards until the yokes of the two magnetic cores contact. The insulating partition 42 can be pre-placed on the base 1 or placed on the coil end face after the coil is in place.

[0048] 4) Fixing and curing: Place the magnetic core fixing clamp 22 on the outside of the assembled magnetic core assembly 2 and apply a stable clamping force. Place the entire assembly at a certain temperature to allow the epoxy resin to cure.

[0049] The working principle of this invention is as follows: When current flows into the flat, vertically wound coil 3 through the solder pins, a magnetic field is generated inside the coil. This magnetic field is mainly confined within a high-permeability closed magnetic circuit composed of two UFY split magnetic cores 21. The high permeability of the magnetic cores reduces the number of ampere-turns required to establish the same magnetic flux, meaning a higher inductance can be obtained with a smaller coil. The material (metal powder core or ferrite) and size of the magnetic core determine the saturation current, inductance, and frequency characteristics of the inductor. The distributed air gap (if a metal powder core is used) ensures that the magnetic field energy is uniformly stored within the core volume, avoiding local hot spots. The flat, vertically wound structure optimizes the distribution of high-frequency current and reduces eddy current and proximity effect losses. Ultimately, electrical energy is efficiently stored or transferred in the form of magnetic energy, achieving functions such as filtering and energy storage.

[0050] This invention, through the modular assembly concept of prefabricated coils and split magnetic cores, combined with designs such as flat vertical winding, UF magnetic circuit, clamping and fixing, and direct soldering pins, solves multiple problems of traditional high-power inductors in terms of process, size, performance and reliability. It is particularly suitable for the fields of vehicle power supply and new energy charging equipment where space, efficiency and reliability requirements are extremely high.

[0051] 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.

[0052] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A combined high-power inductor, characterized in that, include: Base; A magnetic core assembly, which is mounted on the base, the magnetic core assembly comprising two separate magnetic cores arranged opposite each other to form a closed magnetic circuit; At least one flat, vertically wound coil is disposed between the base and the magnetic core assembly. The flat, vertically wound coil is arranged around the cylindrical portion of the split magnetic core, and its lead end extends outward through the base. An insulating assembly, comprising a cylindrical insulating bushing disposed between the column of the split magnetic core and the flat vertically wound coil, and an insulating partition disposed between the end face of the flat vertically wound coil and the yoke of the split magnetic core.

2. The combined high-power inductor according to claim 1, characterized in that: The split magnetic core is a UFY type magnetic core. Each split magnetic core includes an L-shaped yoke and a column extending horizontally from one end of the yoke. The columns of two split magnetic cores are arranged opposite each other, and their yokes together form the main frame of the closed magnetic circuit.

3. The combined high-power inductor according to claim 2, characterized in that: The material of the split magnetic core is metal magnetic powder core or high-permeability ferrite; when metal magnetic powder core is used, it has a distributed air gap inside; when high-permeability ferrite is used, it is used to form a high-inductance common-mode inductor.

4. The combined high-power inductor according to claim 1, characterized in that: The flat, vertically wound coil is formed by vertically winding flat copper wire with a rectangular cross-section along its wide side, and the long side of the cross-section of the wound portion is parallel to the cylindrical axis of the split magnetic core.

5. The combined high-power inductor according to claim 1, characterized in that: It also includes a core fixing clamp, which is located on the outside of the assembled core assembly and is used to provide a clamping force to the two separate cores so that their mating surfaces fit tightly together.

6. The combined high-power inductor according to claim 1, characterized in that: The base is provided with pin holes for the lead ends of the flat vertically wound coil to pass through, and the part of the lead end that passes through the pin holes forms a solder pin for direct soldering to the circuit board.

7. The combined high-power inductor according to claim 1, characterized in that: The two separate magnetic cores are bonded together with epoxy resin adhesive.

8. The combined high-power inductor according to claim 1, characterized in that: At least two flat vertically wound coils are provided, and the at least two flat vertically wound coils are arranged side by side. An insulating partition is provided between two adjacent flat vertically wound coils, and the lead ends of each flat vertically wound coil are led out from the base side by side.

9. The combined high-power inductor according to claim 1, characterized in that: The insulating bushing is made of NOMEX insulating sheet.

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