A reactor and an inverter

Abstract

The application discloses an electric reactor and an inverter, and belongs to the technical field of electrical equipment. The electric reactor in the embodiment of the application comprises a shell, a framework, a magnetic core and a winding. The shell is provided with a communicating open end and a containing cavity. The inner wall of the shell is provided with a boss which is protruding towards the open end and has a containing groove. The framework is arranged in the containing cavity. The magnetic core is arranged on the framework. The winding is arranged on the magnetic core and accommodated in the containing groove. The winding and the boss have a gap therebetween. The boss and the framework have a gap therebetween. The boss is arranged on the inner wall of the shell, the filling amount of the heat-conducting adhesive between the winding and the shell is reduced, the thickness of the heat-conducting adhesive in the gap region between the boss and the winding is reduced, the overall thermal resistance is reduced, the heat can be more quickly conducted from the winding to the shell, and the temperature rise of the electric reactor is effectively improved. Meanwhile, the creepage distance between the winding and the shell is increased through the gap between the boss and the framework, and the dielectric property of the electric reactor is improved.

Description

Technical Field

[0001] This application relates to the field of electrical equipment technology, and more particularly to a reactor and an inverter. Background Technology

[0002] Reactors are crucial components responsible for energy transfer, storage, and filtering. A typical reactor consists of a metal heat sink and an inductor body. The inductor body comprises a magnetic core and windings, which are encapsulated within the metal heat sink using thermally conductive adhesive. However, in related technologies, the thermally conductive adhesive, used as an insulating material, cannot simultaneously maintain the reactor's dielectric properties and heat dissipation capabilities. Utility Model Content

[0003] This application provides a reactor that aims to solve the technical problem that thermally conductive adhesive cannot simultaneously achieve the dielectric properties and heat dissipation capabilities of a reactor.

[0004] Technical solution: This application discloses a reactor, including: A housing having a communicating opening and a receiving cavity, the inner wall of the housing having a boss protruding toward the opening, and the boss having a receiving groove; A skeleton, wherein the skeleton is disposed within the accommodating cavity; A magnetic core, which is disposed on the frame; A winding is wound on the magnetic core and housed in the receiving groove, with a gap between the winding and the boss; There is a gap between the boss and the skeleton.

[0005] In some embodiments, the boss has a bearing surface located on the side of the boss facing the winding, and the bearing surface extends in an arcuate shape along the circumference of the winding.

[0006] In some embodiments, the inner wall of the housing includes a support wall, and the boss protrudes from the support wall; The bearing surface and the supporting wall have a distance d, the winding and the supporting wall have a distance a, and the winding and the boss have a minimum thermal conductivity distance c, satisfying: d≤ac.

[0007] In some embodiments, the frame includes a main body and a plurality of limiting blocks. The main body is disposed on opposite sides of the winding, and the limiting blocks are connected to the side of the main body facing the winding and located between the winding and the housing.

[0008] In some embodiments, a plurality of the limiting blocks are arranged at circumferential intervals along the winding.

[0009] In some embodiments, at least some of the limiting blocks are double-segment limiting blocks, each including a first limiting segment and a second limiting segment. The first limiting segment is connected to the main body and extends circumferentially along the winding. The second limiting segment is connected to the side of the first limiting segment away from the main body and extends in a direction parallel to the axial direction of the winding.

[0010] In some embodiments, the body has a through-hole for excess adhesive, which is located between adjacent limiting blocks.

[0011] In some embodiments, the magnetic core includes a magnetic column, a first magnetic yoke, and a second magnetic yoke, wherein the first magnetic yoke and the second magnetic yoke are spaced apart, the magnetic column is located between the first magnetic yoke and the second magnetic yoke and is respectively connected to the first magnetic yoke and the second magnetic yoke, and the number of magnetic columns is at least one, and each magnetic column is wound with the winding.

[0012] In some embodiments, the reactor further includes thermally conductive adhesive that fills the receiving cavity and submerges the winding.

[0013] This application also discloses an inverter, including the reactor described in the above embodiments.

[0014] Beneficial Effects: The reactor in this embodiment includes a housing, a frame, a magnetic core, and a winding. The housing has a communicating opening and a receiving cavity. A boss is provided on the inner wall of the housing, protruding towards the opening and having a receiving groove. The frame is disposed within the receiving cavity. The magnetic core is disposed on the frame. The winding is wound on the magnetic core and housed within the receiving groove, with a gap between the winding and the boss. A gap also exists between the boss and the frame. By providing a boss on the inner wall of the housing, the amount of thermally conductive adhesive filling between the winding and the housing is reduced. In the gap area between the boss and the winding, the thickness of the thermally conductive adhesive is reduced, the overall thermal resistance is lowered, and heat can be conducted from the winding to the housing more quickly, effectively improving the temperature rise of the reactor. Simultaneously, the gap between the boss and the frame increases the creepage distance between the winding and the housing, improving the dielectric performance of the reactor.

[0015] The inverter of this application embodiment includes the reactor as described in the above embodiment. Therefore, it can have all the technical features and effects of the above-described reactor, which will not be repeated here.

[0016] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0019] Figure 1 This is a three-dimensional structural diagram of the reactor according to an embodiment of this application; Figure 2 This is a top view schematic diagram of the reactor in the embodiment of this application; Figure 3 yes Figure 2 A cross-sectional view along the AA direction; Figure 4 yes Figure 2 A cross-sectional view along the BB direction; Figure 5 This is an assembly diagram of the windings, magnetic core, and frame in the reactor of the embodiment of this application; Figure 6 This is a front view schematic diagram of the reactor frame in an embodiment of this application; Figure 7 This is a three-dimensional structural diagram of the housing in the reactor of this application embodiment, showing the boss and the bearing surface.

[0020] Explanation of reference numerals in the attached figures: 10. Shell; 100. Receiving cavity; 101. Opening; 102. Support wall; 11. Boss; 110. Receiving groove; 20. Frame; 30. Winding; 111. Bearing surface; 21. Main body; 22. Limiting block; 220. Double-segment limiting block; 221. First limiting segment; 222. Second limiting segment; 210. Glue overflow hole; 40. Magnetic core; 41. Magnetic column; 42. First magnetic yoke; 43. Second magnetic yoke. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0022] In the description of this application, it should be understood that the terms "upper," "lower," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. In the description of this application, "multiple" means two or more, and "at least one" can refer to one, two, or more, unless otherwise explicitly specified. The terms "first," "second," and "third," etc., are only for the convenience of description and are used to name components or embodiments by number, and do not imply any order of importance between the components or embodiments.

[0023] In the description of this application, "parallel" means perfectly parallel or nearly perfectly parallel, for example, parallel within a 10° range of perfect parallelism.

[0024] As an introduction to this application, a reactor is an important device that performs functions such as energy transfer, storage, and filtering. A reactor typically includes a metal heat sink and an inductor body. The inductor body includes a magnetic core 40 and a winding 30, which are encapsulated in the metal heat sink using thermally conductive adhesive. In related technologies, the thermally conductive adhesive, as an insulating material, is problematic if its thickness is too thin, affecting the reactor's dielectric properties; conversely, if it is too thick, it significantly impacts the reactor's temperature rise. A greater thickness of the thermally conductive adhesive results in higher dielectric properties, making it difficult for heat to be conducted from the reactor's interior to the metal heat sink, leading to a higher temperature rise – a conflict between the two. Furthermore, in traditional solutions, the dimensions between the winding 30 and the metal casing 10 are difficult to control, requiring the use of pads, tape, etc., to control creepage gaps, resulting in complex processes and difficulties in dimensional control. Moreover, since the pads and adhesive are made of different materials, they cannot fully react and bond, creating gaps at high temperatures that cause creepage and other complex problems that are difficult to resolve.

[0025] In view of this, embodiments of this application provide a reactor aimed at solving at least one of the above-mentioned technical problems.

[0026] Please see Figure 1As shown in the embodiments of this application, the reactor includes a housing 10, a frame 20, a magnetic core 40, and a winding 30. The housing 10 has a communicating opening 101 and a receiving cavity 100. The inner wall of the housing 10 is provided with a boss 11, which protrudes towards the opening 101 and has a receiving groove 110. The frame 20 is disposed in the receiving cavity 100. The winding 30 is wound on the magnetic core 40 and is received in the receiving groove 110. There is a gap between the winding 30 and the boss 11, and there is a gap between the boss 11 and the frame 20. It should be understood that by providing the boss 11 on the inner wall of the housing 10, the amount of thermally conductive adhesive filling between the winding 30 and the housing 10 is reduced. In the gap area between the boss 11 and the winding 30, the thickness of the thermally conductive adhesive is reduced, the overall thermal resistance is reduced, and heat can be conducted from the winding 30 to the housing 10 more quickly, effectively improving the temperature rise of the reactor. Meanwhile, the gap between the boss 11 and the frame 20 increases the creepage distance between the winding 30 and the housing 10, thereby improving the dielectric performance of the reactor. Creepage distance refers to the shortest distance along the surface of the insulating material between two conductive parts. The larger the creepage distance, the better the dielectric performance and the better it can prevent discharge phenomena along the insulating surface.

[0027] It should also be understood that the boss 11 and the housing 10 of this application can be integrally formed. Compared with auxiliary parts such as pads and tapes, the boss 11 reduces the assembly process and reduces the complexity of the process. At the same time, it is easier and more accurate to control the size between the winding 30 and the housing 10, reducing the problem of loose connection caused by material differences, thereby effectively avoiding the creepage phenomenon caused by gaps at high temperatures and improving the insulation reliability of the reactor.

[0028] Please see Figure 4 and Figure 7 As shown, in some embodiments, the boss 11 has a bearing surface 111, which is located on the side of the boss 11 facing the winding 30. The bearing surface 111 extends in an arc shape along the circumference of the winding 30. It should be understood that the bearing surface 111 is mainly used to support the thermally conductive adhesive. By setting the bearing surface 111 of the boss 11 to be an arc shape, a relative relationship between the boss 11 and the winding 30 is formed, and the distance between the boss 11 and the winding 30 remains uniform in the circumferential direction. This ensures a more uniform thickness of the thermally conductive adhesive and ensures the uniformity of thermal conductivity between the winding 30 and the boss 11. At the same time, it makes the creepage path length along the surface of the thermally conductive adhesive consistent in the circumferential direction, reducing the insulation risk caused by excessively short local creepage distances.

[0029] Please see Figure 2 and Figure 3As shown, in some embodiments, the inner wall of the housing 10 includes a support wall 102, and a boss 11 protrudes from the support wall 102; the bearing surface 111 and the support wall 102 have a distance d, the winding 30 and the support wall 102 have a distance a, and the winding 30 and the boss 11 have a minimum thermal conductivity distance c, satisfying: d ≤ ac. It should be understood that the distance d refers to the height of the boss 11 in the protruding direction, or it can be understood as the length of the boss 11 extending from the support wall 102 of the housing 10 into the accommodating cavity 100. The distance a refers to the shortest straight-line distance between the outer surface of the winding 30 and the support wall 102 of the housing 10. The minimum thermal conductivity distance c between the winding 30 and the boss 11 refers to the shortest straight-line distance between the outer surface of the winding 30 and the surface of the boss 11 facing the winding 30, and this distance must meet the minimum requirement for the thermally conductive adhesive to effectively fill and transfer heat. By restricting the above relationship, it is ensured that when the boss 11 is in function, the gap between the winding 30 and the boss 11 can be fully filled by the thermally conductive adhesive. At the same time, the thickness of the thermally conductive adhesive is precisely controlled within a reasonable range, so that the thermal conductivity is not affected by the adhesive layer being too thick, nor is the insulation affected by the adhesive layer being too thin.

[0030] Please see Figure 5 and Figure 6 As shown, in some embodiments, the frame 20 includes a main body 21 and a plurality of limiting blocks 22. The main body 21 is disposed on opposite sides of the winding 30, and the limiting blocks 22 are connected to the side of the main body 21 facing the winding 30 and located between the winding 30 and the housing 10. It should be understood that the limiting blocks 22 limit the outermost turns of the winding 30, ensuring the stability of the position of each turn during winding of the winding 30 and avoiding overall structural deformation caused by inter-turn offset.

[0031] In some embodiments, the limiting block 22 has a thickness h, the winding 30 and the housing 10 have a distance a, and there is a minimum creepage distance f between the winding 30 and the housing 10, satisfying: f ≤ h ≤ a. It should be understood that the thickness h of the limiting block 22 refers to the maximum length of the limiting block 22 in the direction of the winding 30 toward the support wall 102, or, can be understood as the shortest straight-line distance between the limiting block 22 from the surface near the winding 30 to the surface near the support wall 102. By limiting the thickness h of the limiting block 22 to be greater than or equal to the minimum creepage distance f, sufficient insulation distance is ensured between the winding 30 and the housing 10, preventing creepage along the insulating surface, thereby improving the insulation performance of the reactor and reducing the risk of electrical faults due to insulation failure. By limiting the thickness h of the limiting block 22 to be less than or equal to the distance a, it is ensured that during assembly, the limiting block 22 will not interfere with or be squeezed against the housing 10, thus preventing the risk of deformation of the housing 10. When the thickness of the limiting block 22 is less than the distance between the winding 30 and the support wall 102, the distance between the limiting block 22 and the support wall 102 not only provides assembly redundancy, but also provides space for thermally conductive adhesive filling. This ensures the overall structural stability of the reactor and helps maintain the thermal conduction path between the winding 30 and the housing 10, ensuring that heat can be effectively conducted from the winding 30 to the housing 10 through the thermally conductive adhesive.

[0032] Please see Figure 6 As shown, in some embodiments, the main body 21 is provided with multiple limiting blocks 22, and the multiple limiting blocks 22 are arranged at intervals along the circumference of the winding 30. It should be understood that by setting multiple limiting blocks 22 at intervals along the circumference, support and limiting can be provided at different circumferential positions of the winding 30, reducing the risk of radial displacement of the winding 30 during assembly, potting, or operation; at the same time, the winding 30 may vibrate due to electromagnetic force during operation, and the multiple limiting blocks 22 arranged at intervals can distribute the force generated by the vibration to different positions, avoiding excessive force on a single limiting block 22 that could lead to damage or deformation, and improving the vibration resistance and reliability of the overall structure. The intervals between the limiting blocks 22 form the filling gaps of the thermally conductive adhesive, allowing the thermally conductive adhesive to smoothly fill all areas between the winding 30 and the housing 10, including the area around the limiting blocks 22 and the entire circumferential surface of the winding 30, ensuring that the thermally conductive adhesive is in full contact with the winding 30, the housing 10, and the boss 11, forming a complete heat conduction path. The evenly spaced distribution of multiple limiting blocks 22 ensures a more uniform distribution of the thermally conductive adhesive in the circumferential direction of the winding 30, thereby ensuring more uniform heat transfer between the winding 30 and the housing 10. The spaced limiting blocks 22 also guarantee insulation between the winding 30 and the housing 10, and help optimize creepage paths, thus improving insulation reliability.

[0033] Please see Figure 5 and Figure 6As shown, in some embodiments, at least some of the limiting blocks 22 are double-segment limiting blocks 220. Each double-segment limiting block 220 includes a first limiting segment 221 and a second limiting segment 222. The first limiting segment 221 is connected to the main body 21 and extends circumferentially along the winding 30. The second limiting segment 222 is connected to the side of the first limiting segment 221 away from the main body 21 and extends in a direction parallel to the axial direction of the winding 30. It should be understood that the first limiting segment 221 and the second limiting segment 222 form an L-shaped structure. The first limiting segment 221 constrains and limits the first turn of the outermost winding 30, and the second limiting segment 222 constrains and limits the second turn of the winding 30. This segmented design ensures the stability of the position of each turn during winding of the winding 30, avoiding overall structural deformation caused by inter-turn offset. By setting limiting sections only for adjacent turns, compared to a full-coverage limiting structure, the coverage area of ​​the limiting block 22 on the circumference of the winding 30 is significantly reduced. This provides more space for the thermally conductive adhesive to fill, allowing it to make fuller contact with the surface of the winding 30. It also reduces the obstruction of heat conduction by the limiting block 22, lowers thermal resistance, and ultimately reduces the impact on the heat dissipation of the reactor while ensuring the winding accuracy of the winding 30.

[0034] Please see Figure 6 As shown, in some embodiments, the main body 21 has a through-hole 210, which is located between adjacent limiting blocks 22. It should be understood that by providing the overflow hole 210, the potting pressure on both sides of the main body 21 is balanced, which helps to expel air and solves the problem of incomplete filling of thermally conductive adhesive and residual air bubbles in the gap between adjacent limiting blocks 22. Whether there is overflowing thermally conductive adhesive at the overflow hole 210 indicates whether the space between the winding 30 and the housing 10 is completely filled with thermally conductive adhesive, ensuring that the thermally conductive adhesive forms a complete and uniform heat conduction path to guarantee thermal conductivity. This also prevents adhesive accumulation that could cause the winding 30 to shift, while not affecting the insulation and limiting functions of the limiting blocks 22, significantly improving the convenience of the potting process and product consistency.

[0035] Please see Figure 3 and Figure 5As shown, in some embodiments, the magnetic core 40 includes a magnetic column 41, a first magnetic yoke 42, and a second magnetic yoke 43. The first magnetic yoke 42 and the second magnetic yoke 43 are spaced apart. The magnetic column 41 is located between the first magnetic yoke 42 and the second magnetic yoke 43 and is connected to the first magnetic yoke 42 and the second magnetic yoke 43 respectively. There is at least one magnetic column 41, and each magnetic column 41 is wound with a winding 30. It should be understood that the magnetic column 41 connects the two magnetic yokes to form a closed or semi-closed magnetic circuit, and each magnetic column 41 is independently wound with a winding 30. This design can effectively constrain the magnetic flux and reduce magnetic leakage loss. It can accurately adjust the inductance value, improve energy efficiency and power density, disperse electromagnetic force, avoid local overheating, and adapt to the winding 30 winding and overall thermal insulation design, thereby enhancing the reactor's operational stability and structural compactness.

[0036] In some embodiments, the reactor further includes thermally conductive adhesive (not shown in the figure), which fills the receiving cavity 100 and submerges the winding 30. It should be understood that by potting the receiving cavity 100 of the housing 10 with thermally conductive adhesive, air gaps are eliminated, and magnetic leakage is reduced. The thermally conductive adhesive also provides mechanical shock and impact protection, and its excellent thermal conductivity creates a direct heat transfer path between the winding 30 and the housing 10, improving heat dissipation efficiency.

[0037] This application also discloses an inverter, including the reactor as described in the above embodiments. The inverter of this application can have all the technical features and effects of the above-described reactor, which will not be repeated here.

[0038] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0039] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0040] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A reactor, characterized in that, include: The housing (10) has a communicating opening (101) and a receiving cavity (100). The inner wall of the housing (10) is provided with a boss (11), which protrudes toward the opening (101) and has a receiving groove (110). A skeleton (20) is disposed within the receiving cavity (100); A magnetic core (40) is disposed on the frame (20); The winding (30) is wound on the magnetic core (40), the winding (30) is housed in the receiving groove (110), and there is a gap between the winding (30) and the boss (11); There is a gap between the boss (11) and the skeleton (20).

2. The reactor according to claim 1, characterized in that, The boss (11) has a bearing surface (111), which is located on the side of the boss (11) facing the winding (30). The bearing surface (111) extends in an arc shape along the circumference of the winding (30).

3. The reactor according to claim 2, characterized in that, The inner wall of the housing (10) includes a support wall (102), and the boss (11) protrudes from the support wall (102); The bearing surface (111) and the support wall (102) have a distance d, the winding (30) and the support wall (102) have a distance a, and the winding (30) and the boss (11) have a minimum thermal conductivity distance c, satisfying: d≤ac.

4. The reactor according to claim 1, characterized in that, The frame (20) includes a main body (21) and a plurality of limiting blocks (22). The main body (21) is disposed on opposite sides of the winding (30). The limiting blocks (22) are connected to the side of the main body (21) facing the winding (30) and are located between the winding (30) and the housing (10).

5. The reactor according to claim 4, characterized in that, The plurality of the limiting blocks (22) are arranged at circumferential intervals along the winding (30).

6. The reactor according to claim 5, characterized in that, Among the plurality of limiting blocks (22), at least some of the limiting blocks (22) are double-segment limiting blocks (220), the double-segment limiting blocks (220) include a first limiting segment (221) and a second limiting segment (222), the first limiting segment (221) is connected to the main body (21) and extends along the circumference of the winding (30), the second limiting segment (222) is connected to the side of the first limiting segment (221) away from the main body (21), and the second limiting segment (222) extends in a direction parallel to the axial direction of the winding (30).

7. The reactor according to claim 5, characterized in that, The main body (21) has a through-hole (210) for overflowing glue, which is located between adjacent limiting blocks (22).

8. The reactor according to claim 1, characterized in that, The magnetic core (40) includes a magnetic column (41), a first magnetic yoke (42) and a second magnetic yoke (43). The first magnetic yoke (42) and the second magnetic yoke (43) are spaced apart. The magnetic column (41) is located between the first magnetic yoke (42) and the second magnetic yoke (43) and is connected to the first magnetic yoke (42) and the second magnetic yoke (43) respectively. The number of magnetic columns (41) is at least one, and each magnetic column (41) is wound with the winding (30).

9. The reactor according to claim 1, characterized in that, The reactor also includes thermally conductive adhesive that fills the receiving cavity (100) and submerges the winding (30).

10. An inverter, characterized in that, Including the reactor as described in any one of claims 1 to 9.

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