Inverter and cable-free inductor

Abstract

To provide an inverter and a cable-free inductor.SOLUTION: The inverter includes a top housing, a bottom housing, a power inductor, and a main circuit board. The top housing and the bottom housing form an accommodation cavity, and the main circuit board is installed in the accommodation cavity. The bottom housing includes a through hole. The power inductor passes through the through hole to be connected to the main circuit board. The power inductor includes an inductor housing, an inductor cover plate, a magnetic core, and a coil. The inductor housing and the inductor cover plate form an accommodation space, the magnetic core and the coil are located in the accommodation space. The inductor cover plate includes a cover plate body and a connection bracket. The power inductor is rigidly connected to the main circuit board through the connection bracket. Since a connection cable is not needed, a production period is shortened and miniaturization of an apparatus is facilitated.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present application relates to the field of power electronics, in particular inverters and cable-free inductors. [Background technology]

[0002] In recent years, the new energy industry has developed rapidly amid growing concerns about global environmental issues. As one of the new energies, solar energy is widely used due to its characteristics such as abundance, easy accessibility, and cleanness. As one of the important components of a solar power generation system, a solar inverter converts the direct current generated by a solar panel into an alternating current of 220V, 50Hz or other types of alternating current, which can meet the power consumption of various devices. However, at present, there are a large number of connection cables inside the solar inverter, which makes the installation process complicated and prone to cable connection failure. The connection cables inside the inverter need to be connected to the electrical elements through various wiring terminals or pins, which increases the size of the entire solar inverter. At present, the size of the solar inverter is large and the heat dissipation effect is poor. In addition, in the solar cell inverter, the inductor is an essential electrical element. In the manufacturing process of the solar cell inverter, the potting process of the inductor takes up a large part of the manufacturing time. Summary of the Invention

[0003] The present application provides a cable-free inductor and an inverter using the inductor to avoid cable connection errors, simplify installation procedures, shorten manufacturing time, and facilitate device miniaturization.

[0004] According to a first aspect, the present application provides an inverter including an upper housing, a bottom housing, a power inductor, and a main circuit board. The upper housing and the bottom housing are surrounded to form a receiving cavity. The main circuit board is mounted in the receiving cavity, and a surface on which the main circuit board is located is parallel to a surface on which the upper housing is located. The bottom housing includes a through hole. The through hole is configured such that the power inductor passes through the bottom housing along a first direction and connects to the main circuit board. The first direction is a direction perpendicular to the surface on which the main circuit board is located.

[0005] In this implementation, the power inductor is detachable from the inverter, the manufacturing processes of the power inductor and the inverter do not interfere with each other, and the total manufacturing period of the inverter is not constrained by the solidification time of the potting compound of the power inductor. Therefore, the overall production efficiency of the inverter is improved. The upper housing, the main circuit board, and the power inductor are arranged in a stacked manner along the first direction, which reduces the projection area of ​​the entire inverter in the first direction compared with the case where the power inductor and the main circuit board are arranged in parallel, and facilitates the miniaturization of the device. The power inductor is directly connected to the main circuit board. Therefore, the cable is eliminated, the possible cable connection error is avoided, the installation process of the power inductor is simplified, and the process aesthetics of the inverter is improved.

[0006] Regarding the first embodiment, in one implementation, the power inductor includes an inductor housing, an inductor cover plate, a magnetic core, and a coil. The inductor housing and the inductor cover plate are surrounded to form an accommodation space, the magnetic core and the coil are located within the accommodation space, and the coil is wound around the magnetic core. The inductor cover plate includes a connection bracket. The connection bracket is located on a side of the inductor cover plate away from the coil, and the connection bracket is configured to support conductive components between the power inductor and a main circuit board.

[0007] In this implementation, the inside and outside of the power inductor are isolated from each other by the inductor housing and the inductor cover plate. The heat-generating magnetic core and coil are disposed inside the power inductor, and the inductor cover plate on the outside of the power inductor is connected to the main circuit board through the connection bracket. The connection bracket can provide a housing space for the connector and can also support the conductive parts of the power inductor. Furthermore, the connection bracket can be adaptively adjusted based on the specifications of the inductor to facilitate design and installation.

[0008] Regarding the first aspect, in one implementation, the inductor cover plate includes a coil through hole and a conductive metal strip. The coil passes through the inductor cover plate through the coil through hole. One end of the conductive metal strip is connected to a main circuit board, and the other end of the conductive metal strip is connected to the coil. The power inductor is electrically connected to the main circuit board via the conductive metal strip.

[0009] In this implementation, the coil of the power inductor passes through the inductor cover plate to pull out the coil end, and is connected to the conductive metal strip used as the transition part, finally realizing the electrical connection to the main circuit board. The coil end and the conductive metal strip are both rigid structures and are connected via welding, buckles, etc. The installation process is simple and the connection reliability is high. In addition, the conductive metal strip is attached to and supported by the connection bracket. Even if the inverter is subjected to vibration during transportation and installation, the connection between the power inductor and the main circuit board is still reliable.

[0010] Regarding the first aspect, in one implementation, the inductor cover plate includes a magnetic ring. The magnetic ring is fixed to the cover plate body, the magnetic ring is arranged around the connection bracket, and the power line formed by connecting the conductive metal strip and the coil passes through the magnetic ring. In this implementation, the magnetic ring is directly integrated into the inductor cover plate to suppress common mode interference. Compared to conventional inductor cable connection technology, the step of sleeved the magnetic ring on the inductor cable is omitted, and fewer installation steps are performed.

[0011] Regarding the first aspect, in one implementation, the connection bracket includes a hollow structure. The hollow structure includes a nut groove, and a nut is disposed in the nut groove. One end of the main circuit board and one end of the conductive metal strip each have a through-hole structure. The through-hole structure is configured to allow a bolt to pass through and be fastened to the nut, and the power inductor is firmly connected to the main circuit board through the conductive metal strip.

[0012] In this implementation, the main circuit board, the conductive metal strip, and the connection bracket are connected through bolts. It is reliable and easy to connect. In addition, both the electrical connection and the strong connection between the power inductor and the main circuit board are integrated into the conductive metal strip. The solution is simple and easy to implement.

[0013] The connecting bracket is a rectangular column structure. A fixed side wall is provided on the peripheral portion of the connecting bracket, which is close to the surface of the main circuit board, and the fixed side wall is a protruding structure with a notch, the fixed side wall is distributed on three sides of the peripheral portion, and the fixed side wall is distributed on a part of one side of the peripheral portion. In this implementation, a recess used for positioning and accommodating the conductive metal strip is formed on the fixed side wall and the upper portion of the connecting bracket. The fixed side wall allows the conductive metal strip to move into the recess only along a first direction. And the connecting bracket is fixed to the main circuit board by a bolt, and the fixed side wall restricts the conductive metal strip from sliding out of the recess. This design makes the installation of the conductive metal strip and the connecting bracket simple, convenient and practical.

[0014] Regarding the first aspect, in one implementation, the conductive metal strip is a Z-shaped plate-like structure, the coil ports are plate-like structures, the conductive metal strip is perpendicular to the coil ports, the coil ports pass through the conductive metal strip, and the coil ports are fixed to the conductive metal strip.

[0015] In this implementation, as a transition element between the coil and the main circuit board, the conductive metal strip needs to maintain a close connection between both ends of the conductive metal strip and the main circuit board to ensure that the power line between the coil and the main circuit board is maintained. The conductive metal strip is designed as a Z-shaped structure with two bends so that the conductive metal strip can deform when the magnitude of the clamping force from the first direction changes. In this way, even if the deformation of the inverter due to long-time work causes a creep effect on the main circuit board, the conductive metal strip can be tightly attached to the main circuit board, ensuring that the power line will not be disconnected. Also, the conductive metal strip is attached to a connecting bracket to connect the plate-shaped coil end to the main circuit board.

[0016] The coil port may alternatively be a plate-like structure with a buckle interface. The coil port includes a buckle and a port plate. The port plate is a plate-like structure, one end of the port plate is connected to the coil, and the other end of the port plate is connected to the buckle. The buckle and the port plate are integrally formed, and the two buckles are perpendicular to the port plate and parallel to the conductive metal strip, and the two buckles are bent in two opposite directions, and at least one of the two buckles is located on a side of the conductive metal strip facing the main circuit board. One end of the coil port, which is connected to the conductive metal strip, is split from the center, and the split part is bent in two opposite directions to form a buckle structure. The buckle structure passes through the conductive metal strip and is clamped to the conductive metal strip. Compared with the welding connection used between the conductive metal strip and the coil port when the coil end is a plate-like structure, the buckle connection used between the conductive metal strip and the coil end greatly improves the connection reliability between the conductive metal strip and the coil end.

[0017] The bends in the conductive metal strip may include bend notches to enhance the deformation capability of the conductive metal strip.

[0018] In relation to the first aspect, in one implementation, the power inductor includes a seal groove and a seal ring. The seal groove is provided around one side of the inductor housing adjacent to the inductor cover plate, and the seal ring is embedded in the seal groove, and the seal ring is configured to seal the bottom housing and the inductor housing. The seal ring can ensure the sealing reliability of the joint between the inverter and the power inductor.

[0019] In relation to the first aspect, in one implementation, the power inductor includes a potting compound. The potting compound is potted in the accommodation space, and the potting compound is configured to immerse the magnetic core and the coil. The potting compound can accelerate the release of heat generated by the magnetic core and the coil, and can improve the heat dissipation capability of the power inductor.

[0020] In relation to the first aspect, in one implementation, heat dissipation fins are disposed on the outer surfaces of both the bottom housing and the inductor housing. The heat dissipation fins can enhance the ability of the power inductor to dissipate heat to the external environment.

[0021] In relation to the first aspect, in one implementation, the inductor housing and the inductor cover plate are detachable from each other, and the inductor housing is firmly connected to the inductor cover plate via a bolt. The detachable inductor housing and the inductor cover plate can make the potting process easier. The bolt connection method can ensure the connection reliability between the inductor housing and the inductor cover plate.

[0022] In relation to the first aspect, in one implementation, the inductor housing is rigidly connected to the bottom housing via a bolt. In addition to the rigid connection and electrical connection between the power inductor and the main circuit board, the inductor housing of the power inductor is further connected to the bottom housing of the inverter, so that the connection reliability between the power inductor and the main circuit board is improved, and the surface of the bottom housing of the inverter and the surface of the inductor housing are combined into a continuous surface. The inductor housing and the bottom housing are connected via a bolt, which can press the seal ring and ensure that the inside of the inverter is isolated from the external environment.

[0023] In relation to the first aspect, in one implementation, the inverter includes an upper housing, a bottom housing, and a main circuit board. The upper housing is a plate-like structure. The bottom housing is a groove-shaped structure. The main circuit board is arranged parallel to the upper housing and mounted in an internal cavity formed by surrounding the upper housing and the bottom housing. The internal cavity is divided into a first cavity and a second cavity by the main circuit board. The first cavity is a cavity formed between the upper housing and a side of the main circuit board facing the upper housing. The second cavity is a cavity formed between the bottom housing and a side of the main circuit board facing the bottom housing. The main electrical elements of the inverter are mounted in the second cavity. Such main electrical elements, such as power modules or capacitor elements, are relatively large in size and have high heat dissipation requirements. The first cavity is mounted with electrical elements that are small and have low heat dissipation requirements, such as signal indicators, surface-mounted capacitors, and surface-mounted resistors. In this way, the overall size of the photovoltaic inverter 20 can be minimized while still ensuring the heat dissipation requirements of the electrical components.

[0024] Regarding the first aspect, in one implementation, the inductor housing includes a heat dissipation fin, a housing connection, and a positioning pin. The housing connection is located around the opening of the inductor housing and is an annular strip-like structure. A central portion of the annular strip-like structure is configured to mount a magnetic core and a coil of the power inductor. The housing connection and the heat dissipation fin are of an integral structure. The annular strip-like structure has a specific width, on which the positioning pin is designed. Two positioning pins are respectively disposed on both sides of the housing connection, and are configured to position the power inductor in a process of mounting the power inductor to the inverter. The positioning pin structure may be configured to position the power inductor in a process of mounting the power inductor to the inverter.

[0025] Regarding the first aspect, in one implementation, the portion of the power inductor that is immersed in the potting compound includes a coil, a magnetic core, and a framework. There are two coils. Each coil has two coil ends. The framework is partially secured to the cover plate body. A central portion of the framework is configured to house and secure the magnetic core and isolate direct contact between the coil and the magnetic core. The coil is wound around the magnetic core.

[0026] According to a second aspect, the present application provides an inductor device including an inductor housing, an inductor cover plate, a magnetic core, and a coil. The inductor housing and the inductor cover plate are surrounded to form an accommodation space, the magnetic core and the coil are located within the accommodation space, and the coil is wound around the magnetic core. The inductor cover plate includes a connection bracket. The connection bracket is located on a side of the inductor cover plate away from the coil, and the connection bracket is configured to support conductive components between the inductor device and a circuit board.

[0027] Regarding the second aspect, in one implementation, the inductor cover plate includes a coil through hole and a conductive metal strip. The coil passes through the inductor cover plate through the coil through hole. One end of the conductive metal strip is connected to the circuit board and the other end of the conductive metal strip is connected to the coil. The power inductor is electrically connected to the circuit board via the conductive metal strip.

[0028] Regarding the second aspect, in one implementation, the inductor cover plate includes a magnetic ring that is fixed to the cover plate body, the magnetic ring is disposed around the connecting bracket, and a power line formed by connecting the conductive metal strip and the coil passes through the magnetic ring.

[0029] Regarding the second aspect, in one implementation, the connection bracket includes a hollow structure. The hollow structure includes a nut groove, and a nut is disposed in the nut groove. One end of the conductive metal strip includes a through-hole structure. The through-hole structure is configured to allow a bolt to pass through and be fastened to the nut, and the power inductor is rigidly connected to the circuit board through the conductive metal strip.

[0030] Regarding the second aspect, in one implementation, the conductive metal strip is a Z-shaped plate-like structure, the coil ports are plate-like structures, the conductive metal strip is perpendicular to the coil ports, the coil ports pass through the conductive metal strip, and the coil ports are fixed to the conductive metal strip.

[0031] The coil port may alternatively be a plate-like structure with a buckle interface. The coil port includes a buckle and a port plate. The port plate is a plate-like structure, one end of the port plate is connected to the coil, and the other end of the port plate is connected to the buckle. The buckle and the port plate are integrally formed, the two buckles are perpendicular to the port plate and parallel to the conductive metal strip, the two buckles are bent in two opposite directions, and at least one of the two buckles is located on the side of the conductive metal strip facing the main circuit board.

[0032] For the technical solution in the second aspect and the technical effects brought about by the technical solution, please refer to the first aspect, and the details will not be described again here. [Brief description of the drawings]

[0033] [Figure 1] FIG. 1 is a diagram of a photovoltaic power generation system according to an embodiment of the present application.

[0034] [Diagram 2] FIG. 1 is a diagram of the structure of a photovoltaic inverter 20 according to an embodiment of the present application.

[0035] [Diagram 3] FIG. 1 is a front view of a solar power inverter 20 according to an embodiment of the present application.

[0036] [Figure 4] FIG. 1 is a side view of a photovoltaic inverter 20 according to an embodiment of the present application.

[0037] [Diagram 5] FIG. 4 is a diagram showing a cross-sectional structure of the solar power generation inverter 20 shown in FIG.

[0038] [Figure 6] FIG. 2 is an axial side view of a second power inductor according to an embodiment of the present application.

[0039] [Figure 7] FIG. 13 is a side view of a second power inductor with concealed inductor housing according to an embodiment of the present application.

[0040] [Figure 8] FIG. 13 is a front view of a second power inductor with concealed inductor housing according to an embodiment of the present application.

[0041] [Figure 9] FIG. 2 is an axial side view of an inductor cover plate according to an embodiment of the present application.

[0042] [Figure 10] 1 is a diagram of a structure of a connecting bracket according to an embodiment of the present application;

[0043] [Figure 11] FIG. 2 is a diagram of a structure of a connection between a conductive metal strip and a coil end according to an embodiment of the present application.

[0044] [Figure 12] FIG. 2 is an axial side view of a first power inductor according to an embodiment of the present application. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0045] The technical solutions of the present application are described below with reference to the accompanying drawings.

[0046] In the embodiments of the present application, prefixes such as "first", "second" and "third" are used only to distinguish different described objects, and do not constitute any limitation on the position, order, priority, amount, content, etc. of the described objects. In the embodiments of the present application, the use of prefixes, such as ordinal numbers, used to distinguish described objects does not constitute a limitation on the described objects. Please refer to the claims or the context description in the embodiments for the description of the described objects. The use of such prefixes should not constitute a redundant limitation. Furthermore, in the description of the embodiments, unless otherwise specified, "plurality" means two or more.

[0047] In the embodiments of the present application, orientations or positional relationships indicated by the terms "upper", "lower", "left", "right", "front", "rear", "top", "bottom", "inside", "outside", etc. are based on orientations or positional relationships shown in the accompanying drawings and are intended merely to explain and simplify the present application, and do not indicate or imply that a particular device or element is required to have a particular orientation or be constructed and operated in a particular orientation, and therefore cannot be understood as limitations of the present application.

[0048] References to "some embodiments" or the like described herein indicate that one or more embodiments of the present application include a particular feature, structure, or characteristic described with reference to the embodiment. Thus, statements such as "some embodiments" appearing in different places in this specification do not necessarily mean to refer to the same embodiments, but instead mean "one or more, but not all, embodiments," unless specifically emphasized otherwise. The terms "including," "having," and variations thereof all mean "including but not limited to," unless specifically emphasized otherwise.

[0049] In the embodiments of the present application, the same reference numbers represent the same components or parts or components. In the embodiments of the present application, for multiple same parts or components, only one of the parts or components may be used as an example showing the reference numbers in the accompanying drawings. The reference numbers are also applicable to other same parts or components. In addition, the dimensions of the parts or components shown in the accompanying drawings are only examples.

[0050] For ease of understanding, the following first describes relevant technical terms and English abbreviations in the embodiments of this application.

[0051] Photovoltaic inverter: An inverter is a converter that converts direct current into constant frequency constant voltage alternating current or frequency modulated voltage controlled alternating current. A photovoltaic inverter is an inverter that converts the variable direct current generated by solar panels (also called photovoltaic panels) into mains frequency alternating current.

[0052] PCS, power conversion system. The power conversion system controls the charging and discharging process of the battery, can perform AC-DC conversion, and can directly supply power to AC loads when there is no power grid.

[0053] UPS, uninterruptible power supply. An uninterruptible power supply is a device connected between an electronic device and a power supply and configured to prevent the electronic device from being powered off due to peak demand, current control, etc.

[0054] Parallel: "Parallel" as defined in this application is not limited to absolute parallelism. The definition of "parallel" can be understood as basic parallelism. It is acceptable that there is no absolute parallelism due to assembly tolerance, design tolerance, influence of structural flatness, or other factors.

[0055] Vertical: Vertical as defined in this application is not limited to absolute vertical intersection (included angle is 90 degrees). It is acceptable that there is no absolute vertical intersection due to assembly tolerance, design tolerance, influence of structural flatness, or other factors. Error within a small angle range is acceptable. For example, an assembly error range of 80 degrees to 100 degrees can be understood as vertical.

[0056] PV: Abbreviation for photovoltaic, which means generating electricity using solar energy. A PV port is a port connected to a photovoltaic module.

[0057] Common mode interference: Common mode interference means that the amplitude of the interference voltage on the signal cable is the same as that on the return cable of the signal cable (commonly called the signal ground cable). The voltage here uses a nearby object (such as ground, a metal chassis, or a reference ground plane) as a reference potential. The interference current loop flows in a loop that includes the conductor and the reference object.

[0058] Creep Effect: The slow and permanent deformation of a solid material under stress, resulting from a prolonged stress less than the yield strength of the material.

[0059] The embodiments of the present application provide a cable-free inductor and the application of the cable-free inductor in a power conversion device.

[0060] The inductor includes an inductor housing, an inductor cover plate, a magnetic core, and a coil. The inductor housing and the inductor cover plate are surrounded to form an accommodation space, the magnetic core and the coil are located within the accommodation space, and the coil is wound around the magnetic core. The inductor cover plate includes a cover plate body and a connection bracket. The cover plate body has a plate-like shape and is connected to the opening of the inductor housing. The connection bracket is located on a side of the inductor cover plate away from the coil, and the power inductor is configured to be electrically and firmly connected to a circuit board via a conductive metal strip.

[0061] The inductor may be used in a power converter. The power converter includes an upper housing, a bottom housing, a power inductor, and a main circuit board. The upper housing and the bottom housing are surrounded to form a receiving cavity, the main circuit board is mounted in the receiving cavity, and a surface on which the main circuit board is located and a surface on which the upper housing is located are both perpendicular to a first direction. The bottom housing includes a through hole. Along the first direction, the power inductor passes through the through hole and is connected to the main circuit board.

[0062] The cable-free inductor provided in the embodiment of the present application can be detached independently from the power conversion device. Therefore, the manufacturing process of the cable-free inductor and the power conversion device do not interfere with each other, so that the manufacturing period of the entire power conversion device can be shortened. In addition, the cable-free inductor is directly connected to the circuit board, and the cable is omitted. This eliminates the possibility of cable connection errors caused by the cable, simplifies the installation procedure of the power inductor, reduces the size of the entire power conversion device, and improves the process aesthetics of the power conversion device.

[0063] The cable-free inductor provided in the embodiment of the present application can be used in various power conversion devices that require a power inductor. The power conversion device including the cable-free inductor of the present application can be used in application scenarios such as home green power, industrial green power, and solar power station. The power conversion device includes a solar power generation inverter, a power conversion system PCS, and an uninterruptible power supply UPS.

[0064] 1 is a diagram of a photovoltaic power system according to an embodiment of the present application. In one embodiment, the devices in the photovoltaic power system 1 include a photovoltaic module 10, a photovoltaic inverter 20, and an energy storage system 30. Optionally, the photovoltaic power system 1 may further include a power grid 40 and a load 50.

[0065] Specifically, the photovoltaic inverter 20 can convert DC from the photovoltaic module 10 to AC and send the AC to the power grid 40 or the load 50. The photovoltaic inverter 20 can send DC from the photovoltaic module 10 to the energy storage system 30 to charge the energy storage system 30. The energy flow between the photovoltaic inverter 20 and the energy storage system 30 and between the photovoltaic inverter 20 and the power grid 40 is bidirectional. In other words, the photovoltaic inverter 20 can convert DC from the energy storage system 30 to AC and send the AC to the power grid 40 or the load 50; the photovoltaic inverter 20 can send AC from the power grid 40 to the load 50, or convert AC to DC and then send the DC to the energy storage system 30 for charging.

[0066] When the photovoltaic power generation system 1 includes a photovoltaic power generation module 10, a photovoltaic power inverter 20, and an energy storage system 30, the photovoltaic power inverter 20 is mainly configured to connect the photovoltaic power generation module 10 to the energy storage system 30 in order to charge the energy storage system 30. When the photovoltaic power generation system 1 includes a photovoltaic power generation module 10, a photovoltaic power inverter 20, an energy storage system 30, a power grid 40, and a load 50, the photovoltaic power inverter 20 can be configured to connect these devices. For example, the photovoltaic power inverter 20 connects the photovoltaic power generation module 10 to the energy storage system 30. The photovoltaic power inverter 20 connects the photovoltaic power generation module 10 to the power grid 40. The photovoltaic power inverter 20 connects the photovoltaic power generation module 10 to the load 50. The photovoltaic power inverter 20 connects the load 50 to the energy storage system 30.

[0067] The energy storage system 30 in the photovoltaic power generation system 1 can store and release electric energy. For example, the energy storage system 30 can store DC electric energy from the photovoltaic power generation module 10, and the energy storage system 30 can supply power to the power grid 40 or the load 50 using the photovoltaic power generation inverter 20. Therefore, application scenarios of the energy storage system 30 are wide, including but not limited to a residential scenario, an industrial green power scenario, a smart solar power plant scenario, etc.

[0068] From the above description, it can be seen that the photovoltaic power inverter 20 is a converter capable of performing mutual conversion between DC and AC. Specifically, the photovoltaic power inverter 20 may include two DC ports (e.g., DC port 3 and DC port 2) and one AC port. The two DC ports are configured to be connected to the photovoltaic power module 10 and the energy storage system 30, respectively. The AC port may be configured to be connected to the power grid 40 and the load 50. For example, the DC port 3 is configured to be connected to the photovoltaic power module 10, and the DC port 2 is configured to be connected to the energy storage system 30. The AC port may be configured to output AC, and the output AC may be distributed using a distribution box, for example, distributed to the power grid 40 and the load 50.

[0069] The photovoltaic module 10 may feed into the power grid 40 and provide power to the load 50 via the DC port 3. The energy storage system 30 may provide power to the load 50 via the DC port 2. The power grid 40 may provide power to the load 50 via the AC port. In other words, the photovoltaic inverter 20 is a connection hub between the load 50 and the energy modules (which may include the photovoltaic module 10, the energy storage system 30, and the power grid 40).

[0070] Power inductors are one of the main heat generating elements in power converters (including the aforementioned solar cell inverters). In this case, the large heat dissipation requirements of power inductors must be considered when designing the power inductors. In order to enhance the heat dissipation capability of power inductors in power converters using natural heat dissipation, the following two methods are usually used. In method 1, the power converter includes an entire mechanical structure member and an inductor cavity, and the inductor cavity can be independently removed from the entire mechanical structure member. The power inductor is potted in the inductor cavity using a potting compound with good thermal conductivity, and the power inductor leads out a cable connected to the substrate of the entire mechanical structure member. In order to meet the requirements of the IP65 protection level, a sealing rubber strip needs to be further added at the joint between the inductor cavity and the entire mechanical structure member. In method 2, the entire mechanical structure member and the inductor cavity are an integral structure. The inductor cavity is in a separate reserved position in the entire mechanical structure member. The power inductor is potted in the inductor cavity, and the power inductor leads out a cable connected to the substrate of the entire mechanical structure member.

[0071] However, the two methods have obvious problems. In method 1, the inductor cavity is placed outside the entire mechanical structural member, and the seal between the inductor cavity and the entire mechanical structural member needs to be made by using a sealing rubber strip or other sealing methods. In this case, the additional sealing cost increases, the sealing reliability is low, and the size of the entire power conversion device increases. In addition, the power inductor and the substrate are connected through a cable. In this case, the process aesthetics of the device are low, and there is a possibility of cable connection errors. In method 2, a place needs to be reserved in the entire mechanical structural member for the inductor cavity. In this case, the size of the entire power conversion device is also large. In addition, the cable connection reduces the process aesthetics of the device, and there is a possibility of cable connection errors. In addition, during the manufacture of the power conversion device, the power inductor and the potting compound need to be potted in the inductor cavity first, and only after the potting compound is completely solidified can other elements in the power conversion device be assembled. Such a solidification process takes a lot of time, which significantly slows down the manufacturing period of the power conversion device.

[0072] However, in this application, the power inductor is potted in a separate inductor cavity, and the inductor cavity directly serves as part of the heat dissipation housing of the power converter, which fully ensures the huge heat dissipation requirements of the power inductor and improves the sealing reliability of the power converter. And the power inductor is directly connected to the substrate by drawing out the conductive metal strip, which eliminates the possibility of cable connection errors caused by the cable, simplifies the installation procedure of the power inductor, shortens the manufacturing period of the entire power converter, reduces the size of the entire power converter, and greatly improves the process aesthetics of the power converter.

[0073] The cable-free inductor provided in the embodiment of the present application and the solar power inverter 20 including the cable-free inductor will be described in detail below. It should be understood that the solar power inverter 20 is merely an example. The cable-free inductor solution provided in the embodiment of the present application can be applied to other power conversion products including power inductors.

[0074] FIG 2 is a diagram of a structure of a photovoltaic inverter 20 according to an embodiment of the present application. FIG 3 is a front view of a photovoltaic inverter 20 according to an embodiment of the present application. FIG 4 is a side view of a photovoltaic inverter 20 according to an embodiment of the present application. FIG 5 is a diagram of a cross-sectional structure of the photovoltaic inverter 20 shown in FIG 3.

[0075] In one implementation, the solar power inverter 20 includes a top housing 203, a bottom housing 204, a first power inductor 201, a second power inductor 202, and a PV port 205. The top housing 203, the bottom housing 204, the first power inductor 201, and the second power inductor 202 are enclosed together to form an outer surface of the solar power inverter 20 (as shown in FIGS. 2-4), and the PV port 205 is fixed to the bottom housing 204 (as shown in FIGS. 2 and 3). The solar power inverter 20 further includes a main circuit board 206, which is fixed to an internal cavity S of the solar power inverter 20 (as shown in FIG. 5).

[0076] In this implementation, the top housing 203 has a plate-like structure. The main circuit board 206 is arranged parallel to the top housing 203. The bottom housing 204 has a groove-like structure. The main circuit board 206 is arranged close to the top housing 203, so that the internal cavity S of the photovoltaic inverter 20 is divided into a first cavity S1 and a second cavity S2 by the main circuit board 206. The first cavity S1 is a cavity formed between the top housing 203 and a side of the main circuit board 206 facing the top housing 203. The second cavity S2 is a cavity formed between the bottom housing 204 and a side of the main circuit board 206 facing the bottom housing 204. The main electrical components of the photovoltaic inverter 20 are all mounted on the side of the main circuit board 206 facing the bottom housing 204. Such main electric components, such as power modules or capacitor components, are relatively large in size and have high heat dissipation requirements. Electric components, such as signal indicators, surface mount capacitors, and surface mount resistors, that are small in size and have low heat dissipation requirements are mounted on the side of the main circuit board 206 that faces the upper housing 203. Heat dissipation fins are disposed on the side of the bottom housing 204 that is opposite to the main circuit board 206. In this embodiment of the present application, the components with high heat dissipation requirements are disposed close to the bottom housing 204, so that the heat dissipation capability of the photovoltaic inverter 20 is improved. In addition, the bottom housing 204 has a groove-like structure, and the distance between the surface of the groove and the main circuit board 206 is determined by the height of the electric components close to the surface of the groove (the height of the electric components in a direction perpendicular to the main circuit board 206). This minimizes the size of the second cavity S2. The main circuit board 206 is disposed close to the upper housing 203, so that the size of the first cavity S1 is minimized. Therefore, the overall size of the photovoltaic inverter 20 can be minimized while ensuring the heat dissipation requirements of the electrical elements.

[0077] The conventional technology of integrating a power inductor into a solar cell inverter cannot overcome the following problems. Specifically, in the manufacturing process of a solar cell inverter including the packaging process of the potting compound of the power inductor, the packaging of the potting compound of the power inductor usually undergoes a long-term potting compound solidification process. The multiple electric elements in the solar cell inverter should only be assembled after the potting compound of the power inductor has completely solidified. In this case, the packaging process of the potting compound of the power inductor occupies a large part of the total manufacturing period of the solar cell inverter. As a result, the total manufacturing period of the solar cell inverter is too long.

[0078] In this implementation, the bottom housing 204 is provided with reserved through-holes. The conductive components of the first power inductor 201 and the second power inductor 202 are connected to the main circuit board 206 through the reserved through-holes of the bottom housing 204. The housings of the first power inductor 201 and the second power inductor 202 are connected to the bottom housing 204 using bolts, and can be independently removed and attached to the solar power inverter 20. In the manufacturing process of the solar power inverter 20, the first power inductor 201 and the second power inductor 202 can be manufactured, packaged and solidified separately in a factory, and then assembled into the solar power inverter 20 after the manufacturing of the first power inductor 201 and the second power inductor 202 is completed. The manufacturing process of the first power inductor 201 and the second power inductor 202 does not affect the assembly process of other electric elements of the solar power inverter 20. Therefore, the total manufacturing period of the solar power inverter 20 is greatly shortened.

[0079] In addition, heat dissipation fins are arranged on the outer surfaces of the first power inductor 201 and the second power inductor 202. When the photovoltaic power inverter 20 is operating, heat generated by the power inductors can also be released through the heat dissipation fins. The outer surfaces of the first power inductor 201 and the second power inductor 202, the bottom housing 204 and the upper housing 203 are surrounded by connecting with bolts and sealing with a seal ring (not shown in Figs. 2 to 5) to form an internal cavity S. This also meets the sealing requirements of the photovoltaic power inverter 20. See Fig. 5. An inductor coil and an inductor magnetic core are attached inside the first power inductor 201 and the second power inductor 202. The pins drawn out by the inductor coil are directly fixed to the main circuit board 206 through a copper rod. In this way, the first power inductor 201 and the second power inductor 202 are directly connected to the main circuit board 206, so that problems such as cable connection errors and complicated installation that may be caused by cable connection are avoided. In addition, the first power inductor 201 or the second power inductor 202, the main circuit board 206 and the upper housing 203 are sequentially arranged in a direction perpendicular to the main circuit board 206. Compared with the case where the first power inductor 201 or the second power inductor 202 and the main circuit board 206 are arranged on the same plane, the technical solution provided in this embodiment of the present application greatly reduces the projected area of ​​the photovoltaic inverter in a direction perpendicular to the main circuit board 206, and improves the compactness of the arrangement of the electrical elements of the photovoltaic inverter 20. This promotes the miniaturization and strengthening of the photovoltaic inverter 20.

[0080] In one implementation, the first power inductor 201 and the second power inductor 202 can be used as a boost circuit inductor and an inverter circuit inductor, respectively. The boost circuit inductor has three MPPT inputs.

[0081] Hereinafter, the first power inductor 201 and the second power inductor 202 provided in the embodiments of the present application will be described in detail.

[0082] Fig. 6 is an axial view of a second power inductor according to an embodiment of the present application. Fig. 7 is a side view of a second power inductor with a concealed inductor housing according to an embodiment of the present application. Fig. 8 is a front view of a second power inductor with a concealed inductor housing according to an embodiment of the present application.

[0083] In one implementation, referring to FIG. 6, the second power inductor 202 includes an inductor housing 2029 and an inductor cover plate 2021. The inductor housing 2029 and the inductor cover plate 2021 are surrounded to form a receiving space S3. The receiving space S3 receives the magnetic core and coil (not shown in FIG. 6). The inductor cover plate 2021 is detachable with respect to the inductor housing 2029, and the inductor housing 2029 is fixed to the inductor cover plate via a bolt. L202 is a bolt through hole reserved for mounting the bolt. In this implementation, two bolt through holes L202 are respectively disposed at two diagonal ends of the inductor cover plate 2021. During factory manufacturing, the magnetic core and coil of the inductor are disposed in the receiving space S3 first. In this disposing process, the position of the inductor cover plate 2021 needs to match with the inductor housing. In other words, the positions of the two bolt through-holes L202 should correspond to the screw holes (not shown in FIG. 6) reserved in the inductor cover plate 2021. Then, bolts are fastened to the two bolt through-holes L202 to ensure that the inductor housing 2029 and the inductor cover plate 2021 are relatively fixed. Then, the potting compound is potted in the receiving space S3. After the potting compound is completely solidified, the second power inductor 202 can be assembled to the photovoltaic inverter 20.

[0084] In this implementation, the inductor housing 2029 includes heat dissipation fins 2027, a housing connection part 2026, and a positioning pin 2028. Most of the outer surface of the inductor housing 2029 is designed to be heat dissipation fins. This helps to quickly and efficiently release the heat generated by the power inductor in the inductor housing 2029, control the temperature of the solar power inverter 20 to be within a proper range, and ensure that the solar power inverter 20 can operate normally for a long time. In the working process of the solar power inverter, the power inductor continuously dissipates heat to the outside. The heat is first transferred to the potting compound. The heat is transferred relatively evenly to the inner surface of the inductor housing 2029 due to the diffusion of the potting compound. After the heat is transferred to the heat dissipation fins 2027 in the thermal conduction process of the material of the inductor housing 2029, it is quickly released to the surrounding environment. The housing connection part 2026 is located around the opening of the inductor housing 2029 and is an annular strip-like structure. The central part of the annular strip-like structure is configured to mount the magnetic core and coil of the power inductor. The housing connection part 2026 and the heat dissipation fins 2027 are of an integral structure. The annular strip-like structure has a certain width, on which the positioning pin 2028, the screw hole L201, the screw hole corresponding to the bolt through hole L202, and the seal ring groove 2030 are designed. There are two positioning pins 2028 respectively arranged on the opposite side of the housing connection part, which are configured for positioning in the process of mounting the second power inductor 202 to the photovoltaic inverter 20. There are four screw holes L201, two of which are arranged on the opposite side of the housing connection part, which are configured for fastening between the bolts of the bottom housing 204. The seal ring groove 2030 is configured to accommodate a seal ring to enhance the sealing between the bottom housing 204 and the second power inductor 202.

[0085] In this implementation, the inductor cover plate 2021 includes a magnetic ring 2025, a conductive metal strip 2023, a connection bracket 2024, and a cover plate body 2022. The cover plate body 2022 is a plate-like structure. There is a coil through-hole in the cover plate body 2022 so that the coil end 2031 can pass through the cover plate body 2022. The coil end 2031 is a terminal drawn out by two ends of the coil 2034 (as shown in Figures 7 and 8), which is a long strip plate-like structure and is configured to realize the electrical connection to the main circuit board 206. In order to realize the cable-free electrical connection between the power inductor and the main circuit board 206, a solution combining the conductive metal strip 2023 and the connection bracket 2024 is used in the embodiment of the present application. The conductive metal strip 2023 is a Z-shaped plate-like structure. A through-hole is provided at one end of the conductive metal strip 2023 to allow the coil end 2031 to be inserted vertically into the through-hole. The connection between the conductive metal strip 2023 and the coil end 2031 is fixed by welding. The other end of the conductive metal strip 2023 is provided with a screw through hole. The connection bracket 2024 is a columnar structure and is integrated with the cover plate body 2022. A screw hole is provided in the center of the connection bracket 2024. During installation, the screw hole, the screw through hole at the other end of the conductive metal strip 2023, and the screw through hole of the main circuit board 206 overlap each other to allow the bolt to pass through the main circuit board 206, the conductive metal strip 2023, and the connection bracket 2024. In this implementation, the connection bracket 2024 can have both the function of supporting the conductive metal strip 2023 and the function of accommodating the connection parts. Please refer to FIG. 7 in particular. The bending angle of the Z-shaped structure of the conductive metal strip 2023 is an acute angle. This reduces the design tolerance requirements of the power inductor since the conductive metal strip 2023 has a certain deformation space at the connection part perpendicular to the cover plate body 2022 and parallel to the coil end 2031.The magnetic ring 2025 is sleeved on the outside of the coil end 2031, the conductive metal strip 2023, and the connection bracket 2024, so that the current path formed between the coil 2034 and the main circuit board 206 passes through the center of the magnetic ring 2025 to suppress common mode interference. The magnetic ring 2025 is connected to the cover plate body 2022 by adhesive bonding. In particular, a fixing protrusion (not shown in FIG. 6) is further disposed on the cover plate body 2022. The fixing protrusion and the cover plate body 2022 are integrally formed to provide positioning of the magnetic ring 2025 for mounting and to limit the movement of the magnetic ring 2025 along the surface of the cover plate body 2022. In another optional implementation, the magnetic ring 2025 can be positioned, limited, and fixed using a buckle.

[0086] After the potting compound is completely solidified, when the second power inductor 202 is installed in the photovoltaic inverter 20, the seal ring already placed in the seal ring groove 2030 is first aligned with the corresponding locating pin hole of the bottom housing 204 based on the locating pin 2028, and then fixed with the four screw holes L201 from the side of the bottom housing 204 using bolts. The seal ring fills the gap between the inductor housing and the bottom housing 204 by fastening and squeezing with the bolts, and isolates the inside of the photovoltaic inverter 20 from the outside of the photovoltaic inverter 20. Then, the connection bracket is fixed to the main circuit board 206 by using bolts, and the part of the main circuit board 206 corresponding to the connection bracket becomes conductive. This forms a current path from the coil 2034 to the coil end 2031, the conductive metal strip 2023, and the main circuit board 206. Therefore, a cable-free electrical connection between the second power inductor 202 and the main circuit board 206 is realized.

[0087] In one implementation, referring to FIG. 7 and FIG. 8, the portion of the second power inductor 202 that is immersed in the potting compound includes a coil 2034, a magnetic core 2032, and a framework 2033. In this implementation, there are two coils 2034. Each coil 2034 leads out two coil ends 2031. The framework 2033 is partially fixed to the cover plate body 2022. The center of the framework 2033 is configured to accommodate and fix the magnetic core 2032 and isolate the direct contact between the coil 2034 and the magnetic core. The coil 2034 is wound around the magnetic core 2032. It should be understood that the amount of the coil 2034, the shape of the magnetic core 2032, the amount of the coil ends 2031 led out by the coil 2034, and the way in which they are led out can be adaptively changed based on the shape of the circuit. This is not limited in the present application.

[0088] In the technical solution provided in the aforementioned embodiment of the present application, after the second power inductor 202 is fixed to the bottom housing 204 and the main circuit board 206 through the bolts, in the first aspect, the coil end 2031 and the conductive metal strip 2023 are not of an integral structure, so that a relatively large force may occur at the joint between the coil end 2031 and the conductive metal strip 2023. In order to increase the reliability of the connection between the coil end 2031 and the conductive metal strip 2023 and further reduce the design tolerance requirements, the present application provides another embodiment of the inductor cover plate 2021. In the second aspect, a creep effect may occur on the main circuit board 206. As a result, the contact resistance between the conductive metal strip 2023 and the main circuit board 206 increases, and poor contact between the two occurs. When the photovoltaic inverter is operated, the temperature of the joint between the two will rise relatively quickly. In the severe case, a fire will occur. In order to reduce the impact of the creep effect on the main circuit board 206, the present application provides another embodiment of the inductor cover plate 2021.

[0089] Fig. 9 is an axial view of an inductor cover plate according to an embodiment of the present application; Fig. 10 is a view of a structure of a connection bracket according to an embodiment of the present application; Fig. 11 is a view of a structure of a connection between a conductive metal strip and a coil end according to an embodiment of the present application.

[0090] In one implementation, referring to FIG. 9, the inductor cover plate 2021 includes a magnetic ring 2025, a conductive metal strip 2023, a connection bracket 2024, and a cover plate body 2022. The relative positional relationship between the magnetic ring 2025, the conductive metal strip 2023, the connection bracket 2024, and the cover plate body 2022, as well as the structural form of the magnetic ring 2025 and the cover plate body 2022 are similar to those of the embodiment shown in FIG. 6. For the sake of brevity, the details are not described again here. The difference is that in the first embodiment, in order to simplify the installation process and improve the reliability of the connection between the conductive metal strip 2023 and the connection bracket 2024, this implementation provides a structural design for matching the conductive metal strip 2023 and the connection bracket 2024. In the second aspect, in order to reduce the contact resistance between the conductive metal strip 2023 and the main circuit board 206, this implementation provides a structural design of the bent portion of the conductive metal strip 2023. In a third aspect, in order to improve the reliability of the connection between the coil end 2031 and the conductive metal strip 2023, this implementation provides a structural design of the connection between the conductive metal strip 2023 and the coil end.

[0091] The three structural designs are described in detail below with reference to the accompanying drawings.

[0092] Please refer to FIG. 10. The connection bracket 2024 includes a nut groove 20242 and a fixed side wall 20241. The nut groove 20242 is located in a hollow portion of the connection bracket 2024 that is close to the main circuit board 206. The nut groove 20242 is configured to receive a nut and cooperates with a bolt to realize a fastening connection between the connection bracket 2024, the conductive metal strip 2023, and the main circuit board 206. In one implementation, a flange nut may be disposed in the nut groove, and the contact area between the flange nut and the conductive metal strip is relatively large. This helps to ensure that the conductive metal strip is not deformed for a long time. The fixed side wall 20241 is located at the upper end of the connection bracket 2024 that is connected to the conductive metal strip 2023. The main part of the fixed side wall 20241 is located on three sides of the four sides of the upper end of the rectangle of the connection bracket 2024, and the fixed side wall and the connection bracket 2024 are integrally formed. The fixed side wall 20241 further includes a notch side wall 20241A. The notch side wall 20241A is located on the other side than the three sides of the four sides of the rectangle. The length of the notch side wall 20241A occupies only a small part of the length of the side where the fixed side wall 20241 is located. In this case, the notch side wall 20241A is surrounded to form a groove with a notch. After the conductive metal strip 2023 is embedded in the groove, the presence of the fixed side wall 20241 limits the movement of the conductive metal strip 2023 on a plane parallel to the main circuit board 206. Due to the presence of the fixed side wall 20241, the work of the connection bracket 2024 being positioned by the conductive metal strip 2023 can be facilitated, and the installation process can be simplified. In addition, the connection between the conductive metal strip 2023 and the connection bracket 2024 is more reliable.

[0093] Refer to FIG. 11. The conductive metal strip 2023 includes a bend notch 20231 and a bolt connection 20232. Refer to FIG. 7, the conductive metal strip 2023 is a Z-shaped structure. Two bend notches 20231 are provided at a bend of the conductive metal strip 2023 that is close to the main circuit board 206. Due to the presence of the bend notches 20231, the deformation ability of the bend where the bend notches 20231 are located can be greatly improved. In one implementation of the present application, the bend of the conductive metal strip that includes the bend notches 20231 can be deformed in a direction perpendicular to the plane where the main circuit board is located, so that the conductive metal strip 2023 always maintains contact with the main circuit board 206. Thus, an excessively large contact resistance at the joint between the conductive metal strip 2023 and the main circuit board 206 is avoided. The bolt connection 20232 further includes a recessed portion 20232A. The shape of the recessed portion 20232A matches the shape of the notch sidewall 20241 A. When the conductive metal strip 2023 is fixed to the connecting bracket 2024, the recessed portion 20232A and the notch sidewall 20241 A are connected to each other.

[0094] Please refer to FIG. 11 further. The coil end 2031 includes a buckle 20311 and a port plate 20312. The port plate 20312 is a long rectangular strip-like structure. One end of the port plate is connected to the coil 2034 (not shown in FIG. 11), and the other end of the port plate 20312 is branched from the center to form two buckles 20311. In this implementation of the present application, the two buckles 20311 are bent in two opposite directions respectively, and the two buckles 20311 are perpendicular to the port plate 20312. A notch is provided at one end of the conductive metal strip 2023, which is connected to the coil end 2031. During connection, the two buckles 20311 pass through the notch, so that the conductive metal strip 2023 and the coil end 2031 are connected to each other. Therefore, the reliability of the connection between the conductive metal strip 2023 and the coil end 2031 is greatly improved. It should be understood that the number of buckles 20311 (e.g., three) and the bending direction of the buckles 20311 (e.g., two buckles bent in the same direction) can vary and are not limited by this application.

[0095] FIG. 12 is an axial side view of a first power inductor according to an embodiment of the present application.

[0096] In one implementation, the first power inductor 201 includes an inductor housing 2029 (not shown in FIG. 12) and an inductor cover plate 2021. The inductor cover plate 2021 includes a cover plate body 2022, a connection bracket 2024, and a conductive metal strip 2023. For brevity, the first power inductor 201 has a similar structure to the second power inductor 202. The details will not be described again here. The difference is that the first power inductor 201 includes three coils (not shown in FIG. 12) because the first power inductor is a boost circuit inductor and has three MPPT inputs. The three coils lead out six coil ends 2031. There are six connection brackets 2024 and six conductive metal strips 2023 to match the six coil ends 2031, and the six connection brackets are symmetrically arranged on the cover plate body 2022. Since the first power inductor 201 and the second power inductor 202 are arranged in different circuits, the first power inductor 201 does not include a magnetic ring.

[0097] In the actual application process, the quantity of the power inductor can be changed according to the different circuit structures of the photovoltaic inverter. Alternatively, the quantity of the coils of the power inductor and the specific structural form of the cover plate body can be adaptively changed according to the different functions of the power inductor in the circuit and the different specifications of the power inductor. It should be understood that the above changes do not exceed the protection scope of the present application.

[0098] The photovoltaic inverter and cable-free power inductor provided in the embodiments of the present application have been described in detail above. In this specification, the principles and embodiments of the present application are described with specific examples. The description of the above embodiments is only provided to help understand the method and core idea of ​​the present application. Furthermore, those skilled in the art can make modifications and changes to specific embodiments and application scope according to the ideas of the present application.

[0099] The above description is merely a specific embodiment of the present application, and is not intended to limit the scope of protection of the present application. Any variations or replacements that are easily understood by those skilled in the art within the technical scope disclosed in the present application shall be included in the scope of protection of the present application. Therefore, the scope of protection of the present application shall be subject to the scope of protection of the claims.

Claims

1. An inverter having an upper housing, a bottom housing, a power inductor, and a main circuit board, The upper housing and the bottom housing are surrounded to form an accommodating cavity, the main circuit board is mounted in the accommodating cavity, and a surface on which the main circuit board is located is parallel to a surface on which the upper housing is located; The bottom housing has a through hole, and the through hole is configured so that the power inductor passes through the bottom housing along a first direction and connects to the main circuit board, the first direction being perpendicular to the plane on which the main circuit board is located. Inverter.

2. The power inductor includes an inductor housing, an inductor cover plate, a magnetic core, and a coil, the inductor housing and the inductor cover plate are surrounded to form an accommodating space, the magnetic core and the coil are located in the accommodating space, and the coil is wound around the magnetic core; the inductor cover plate has a connection bracket located on a side of the inductor cover plate away from the coil, the connection bracket being configured to support conductive components between the power inductor and the main circuit board. The inverter according to claim 1 .

3. the inductor cover plate has a coil through hole and a conductive metal strip, the coil passes through the inductor cover plate through the coil through hole, one end of the conductive metal strip is connected to the main circuit board, and the other end of the conductive metal strip is connected to the coil, and the power inductor is electrically connected to the main circuit board via the conductive metal strip; The inverter according to claim 2 .

4. the inductor cover plate has a magnetic ring, the magnetic ring is fixed to the inductor cover plate, the magnetic ring is arranged around the connecting bracket, and a power line formed by connecting the conductive metal strip and the coil passes through the magnetic ring; The inverter according to claim 3 .

5. The connecting bracket has a hollow structure, the hollow structure includes a nut groove, and a nut is disposed in the nut groove; one end of the main circuit board and one end of the conductive metal strip respectively have a through-hole structure, and the through-hole structure is configured to allow a bolt to pass through and be fastened to the nut; and the power inductor is firmly connected to the main circuit board through the conductive metal strip. The inverter according to claim 2 .

6. The connecting bracket has a rectangular column structure, and a fixed side wall is provided on a peripheral portion of the connecting bracket that is adjacent to a surface of the main circuit board, and the fixed side wall has a protruding structure having a notch, and the fixed side wall is distributed on three sides of the peripheral portion, and the fixed side wall is distributed on a part of the other side of the peripheral portion. The inverter according to claim 5 .

7. The conductive metal strip is a Z-shaped plate-like structure, the port of the coil is a plate-like structure, the conductive metal strip is perpendicular to the port of the coil, the port of the coil passes through the conductive metal strip, and the port of the coil is fixed to the conductive metal strip; The inverter according to claim 3 .

8. The conductive metal strip is a Z-shaped plate-like structure, and the port of the coil has a buckle and a port plate, the port plate is a plate-like structure, one end of the port plate is connected to the coil, and the other end of the port plate is connected to the buckle; the buckle and the port plate are integrally formed, two buckles are perpendicular to the port plate and parallel to the conductive metal strip, the two buckles are bent in two opposite directions, and at least one of the two buckles is located on a side of the conductive metal strip facing the main circuit board; The inverter according to claim 3 .

9. The conductive metal strip of the Z-shaped plate structure has two bends, and at least one of the two bends includes a bend notch.

9. The inverter according to claim 7 or 8.

10. the power inductor has a seal groove and a seal ring, the seal groove being disposed around one side of the inductor housing adjacent to the inductor cover plate, the seal ring being embedded in the seal groove, and the seal ring being configured to seal the bottom housing and the inductor housing; The inverter according to claim 2 .

11. The power inductor has a potting compound, the potting compound is potted in the accommodation space, and the potting compound is configured to immerse the magnetic core and the coil. The inverter according to claim 2 .

12. Heat dissipation fins are disposed on the outer surfaces of both the bottom housing and the inductor housing. The inverter according to claim 2 .

13. The inductor housing and the inductor cover plate are removable from each other, and the inductor housing is rigidly connected to the inductor cover plate via bolts. The inverter according to claim 2 .

14. The inductor housing is rigidly connected to the bottom housing via bolts. The inverter according to claim 2 .

15. 1. An inductor device, comprising: The inductor device includes an inductor housing, an inductor cover plate, a magnetic core, and a coil, the inductor housing and the inductor cover plate are surrounded to form an accommodating space, the magnetic core and the coil are located in the accommodating space, and the coil is wound around the magnetic core; the inductor cover plate has a connection bracket located on a side of the inductor cover plate away from the coil, the connection bracket being configured to support conductive components between the inductor device and a circuit board. Inductor device.

16. the inductor cover plate has a coil through hole and a conductive metal strip, the coil passes through the inductor cover plate through the coil through hole, one end of the conductive metal strip is connected to the circuit board, and the other end of the conductive metal strip is connected to the coil, and the power inductor is electrically connected to the circuit board via the conductive metal strip.

16. The inductor device of claim 15.

17. the inductor cover plate has a magnetic ring, the magnetic ring is fixed to the inductor cover plate, the magnetic ring is arranged around the connecting bracket, and a power line formed by connecting the conductive metal strip and the coil passes through the magnetic ring; 17. The inductor device of claim 16.

18. The connecting bracket has a hollow structure, the hollow structure includes a nut groove, and a nut is disposed in the nut groove; one end of the conductive metal strip has a through-hole structure, and the through-hole structure is configured to allow a bolt to pass through and be fastened to the nut; and the power inductor is rigidly connected to the circuit board through the conductive metal strip.

17. The inductor device of claim 16.

19. The conductive metal strip is a Z-shaped plate-like structure, the ports of the coil are plate-like structures, the conductive metal strip is perpendicular to the ports of the coil, the ports of the coil pass through the conductive metal strip, and the ports of the coil are fixed to the conductive metal strip; 17. The inductor device of claim 16.

20. The conductive metal strip is a Z-shaped plate-like structure, and the port of the coil has a buckle and a port plate, the port plate is a plate-like structure, one end of the port plate is connected to the coil, and the other end of the port plate is connected to the buckle; the buckle and the port plate are integrally formed, two buckles are perpendicular to the port plate and parallel to the conductive metal strip, the two buckles are bent in two opposite directions, and at least one of the two buckles is located on a side of the conductive metal strip facing the circuit board.

17. The inductor device of claim 16.

Images