Inverters and cable-free inductors

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] This application relates to the field of power electronics, particularly inverters and cable-free inductors.

Background Art

[0002] With the increasing concerns about global environmental problems, in recent years, the new energy industry has been rapidly developing. As one of the new energies, solar energy is widely used due to its abundance, easy accessibility, cleanliness, etc. As an important component of a solar power generation system, a solar inverter converts the direct current generated by solar panels into an alternating current of 220V, 50Hz or other types of alternating current, and can meet the power consumption of various devices. However, currently, there are a large number of connection cables inside the solar inverter, the installation process is complex, and cable connection failures are likely to occur. The connection cables inside the inverter need to be connected to electrical components via various wiring terminals or pins, which increases the overall size of the solar inverter. Currently, the size of the solar inverter is large and the heat dissipation effect is poor. Also, in a solar cell inverter, an inductor is an essential electrical component. In the manufacturing process of a solar cell inverter, the potting process of the inductor occupies a lot of manufacturing time.

Summary of the Invention

[0003] This application provides a cable-free inductor and an inverter using the inductor to avoid cable connection errors, simplify the installation procedure, shorten the manufacturing period, and facilitate the miniaturization of the device.

[0004] According to a first aspect, the present application provides an inverter comprising an upper housing, a bottom housing, a power inductor, and a main circuit board. The upper housing and the bottom housing are enclosed to form a housing cavity. The main circuit board is mounted within the housing cavity, and the plane on which the main circuit board is located is parallel to the plane on which the upper housing is located. The bottom housing includes a through hole. The through hole is configured such that a power inductor passes through the bottom housing along a first direction and connects to the main circuit board. The first direction is perpendicular to the plane 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 inverter do not interfere with each other, and the total manufacturing time 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, main circuit board, and power inductor are stacked along a first direction, which reduces the projected area of ​​the entire inverter in the first direction compared to when the power inductor and main circuit board are arranged in parallel, facilitating miniaturization of the device. The power inductor is directly connected to the main circuit board. Therefore, cables are eliminated, potential cable connection errors are avoided, the power inductor installation process is simplified, and the process aesthetics of the inverter are improved.

[0006] In a first embodiment, one implementation includes an inductor housing, an inductor cover plate, a magnetic core, and a coil. The inductor housing and the inductor cover plate are enclosed to form a housing space, the magnetic core and the coil are located within the housing space, and the coil is wound around the magnetic core. The inductor cover plate includes a connection bracket. The connection bracket is located on the side of the inductor cover plate, away from the coil, and is configured to support conductive components between the power inductor and the 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 inductor cover plate. The heat-generating magnetic core and coil are located inside the power inductor, and the inductor cover plate on the outside of the power inductor is connected to the main circuit board via a connection bracket. The connection bracket can provide space for a connector and can also support the conductive components 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] In a first embodiment, in one implementation, the inductor cover plate includes a coil through-hole and a conductive metal strip. The coil passes through the coil through-hole and through the inductor cover plate. 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. The power inductor is electrically connected to the main circuit board via the conductive metal strip.

[0009] In this implementation, the power inductor coil passes through the inductor cover plate, its coil ends are brought out and connected to a conductive metal strip used as a transition, and finally, an electrical connection is made to the main circuit board. Both the coil ends and the conductive metal strip are rigid structures and are connected via welding or buckles. The installation process is simple and the connection reliability is high. The conductive metal strip is mounted on a connection bracket and supported by the connection bracket. Even if the inverter is subjected to vibration during transport and installation, the connection between the power inductor and the main circuit board remains highly reliable.

[0010] In a first embodiment, in one implementation, the inductor cover plate includes a magnetic ring. The magnetic ring is fixed to the cover plate body and is positioned around the connection bracket, and power lines formed by connecting a conductive metal strip and a coil pass through the magnetic ring. In this implementation, to suppress common-mode interference, the magnetic ring is directly integrated into the inductor cover plate. Compared to conventional inductor cable connection techniques, the process of sleeve-forming the magnetic ring onto the inductor cable is omitted, resulting in fewer installation steps.

[0011] In a first embodiment, in one implementation, the connecting bracket includes a hollow structure. The hollow structure is provided with a nut groove, in which a nut is positioned. 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 a nut, and the power inductor is firmly connected to the main circuit board via the conductive metal strip.

[0012] In this implementation, the main circuit board, conductive metal strip, and connecting bracket are connected via bolts. This method is highly reliable and easy to connect. Furthermore, both the electrical connection and the robust connection between the power inductor and the main circuit board are integrated into the conductive metal strip. The solution is simple and highly feasible.

[0013] The connecting bracket has a prism structure. Fixed sidewalls are provided on the periphery of the connecting bracket, near the surface of the main circuit board. The fixed sidewalls are projections with notches, distributed along three sides of the periphery, and also along a portion of one side of the periphery. In this implementation, recesses used to position and accommodate the conductive metal strip are formed on the fixed sidewalls and the top of the connecting bracket. The fixed sidewalls allow the conductive metal strip to move into the recesses only along a first direction. The connecting bracket is also fixed to the main circuit board by bolts, and the fixed sidewalls restrict the conductive metal strip from sliding out of the recesses. This design makes the installation of the conductive metal strip and connecting bracket simple, convenient, and practical.

[0014] In the first embodiment, in one implementation, the conductive metal strip is a Z-shaped plate structure. The port of the coil is a plate 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.

[0015] In this implementation, the conductive metal strip, acting as a transition element between the coil and the main circuit board, needs to maintain a close connection between both ends of the conductive metal strip and the main circuit board to ensure that the power lines between the coil and the main circuit board are maintained. The conductive metal strip is designed as a Z-shaped structure with two bends so that it can deform when the magnitude of the clamping force from a first direction changes. This method ensures that even if creep effect occurs in the main circuit board due to deformation of the inverter during prolonged operation, the conductive metal strip can remain in close contact with the main circuit board, and the power lines will not be disconnected. The conductive metal strip is also attached to a connecting bracket and connects the plate-shaped coil ends to the main circuit board.

[0016] The port of the coil may alternatively be a plate-like structure with a buckle interface. The port of the coil includes a buckle and a port plate. The port plate is a plate-like structure, with one end of the port plate connected to the coil and the other end connected to the buckle. The buckle and port plate are integrally formed, with two buckles perpendicular to the port plate and parallel to the conductive metal strip, and the two buckles are bent in two opposite directions, with at least one of the two buckles located on the side of the conductive metal strip, facing the main circuit board. One end of the port of the coil, the end connected to the conductive metal strip, is divided in the middle, and the divided portion is bent in two opposite directions to form the buckle structure. The buckle structure passes through the conductive metal strip and is clamped to the conductive metal strip. When the coil end is a plate-like structure, the buckle connection used between the conductive metal strip and the coil end significantly improves the connection reliability between the conductive metal strip and the coil end compared to the welded connection used between the conductive metal strip and the port of the coil.

[0017] The bent portion of the conductive metal strip may be provided with a bend notch to enhance the deformation capacity of the conductive metal strip.

[0018] In relation to the first embodiment, 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, the side adjacent to the inductor cover plate, and the seal ring is embedded in the seal groove and configured to seal the bottom housing and the inductor housing. The seal ring can ensure the sealing reliability of the junction between the inverter and the power inductor.

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

[0020] In relation to the first embodiment, in one implementation, heat sinks are arranged on the outer surfaces of both the bottom housing and the inductor housing. The heat sinks can enhance the power inductor's ability to dissipate heat to the external environment.

[0021] In relation to the first embodiment, 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 bolts. The detachable inductor housing and inductor cover plate can simplify the potting process. The bolt connection method can ensure 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 firmly connected to the bottom housing via bolts. In addition to the firm 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, thereby improving the connection reliability between the power inductor and the main circuit board, and combining the surface of the bottom housing of the inverter and the surface of the inductor housing into a continuous plane. The inductor housing and the bottom housing are connected via bolts, which can compress the sealing ring and ensure that the inside of the inverter is isolated from the external environment.

[0023] In relation to the first embodiment, in one implementation, the inverter includes an upper housing, a bottom housing, and a main circuit board. The upper housing has a plate-like structure. The bottom housing has a groove-shaped structure. The main circuit board is positioned parallel to the upper housing and mounted in an internal cavity formed by enclosing the upper and bottom housings. The internal cavity is divided into a first cavity and a second cavity by the main circuit board. The first cavity is formed between the upper housing and the side of the main circuit board that faces the upper housing. The second cavity is formed between the bottom housing and the side of the main circuit board that faces 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. Small electrical elements with low heat dissipation requirements, such as signal indicators, surface mount capacitors, and surface mount resistors, are mounted in the first cavity. This method allows for minimizing the overall size of the solar power inverter 20 while also ensuring adequate heat dissipation for the electrical components.

[0024] In a first embodiment, in one implementation, the inductor housing includes a heat sink, a housing connector, and positioning pins. The housing connector is located around the opening of the inductor housing 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 connector and the heat sink are a single integrated structure. The annular strip-like structure has a specific width on which positioning pins are designed. Two positioning pins are located on either side of the housing connector and are configured to position the power inductor during the process of mounting it to the inverter. The positioning pin structure may be configured to position the power inductor during the process of mounting it to the inverter.

[0025] Regarding the first aspect, in one implementation, the part 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 drawn out. The framework is partially fixed to the cover plate body. The central part of the framework is configured to accommodate and fix 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 the 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 portion of the inductor cover plate away from the coil, and the connection bracket is configured to support a conductive component between the inductor device and the 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. The magnetic ring is fixed to the cover plate body, the magnetic ring is disposed around the connection bracket, and power lines formed by connecting the conductive metal strip and the coil pass through the magnetic ring.

[0029] Regarding the second aspect, in one implementation, the connection bracket includes a hollow structure. The hollow structure has a nut groove, and a nut is arranged 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 firmly connected to the circuit board via the conductive metal strip.

[0030] Regarding the second aspect, in one implementation, the conductive metal strip has a Z-shaped plate structure. The port of the coil has a plate 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.

[0031] The port of the coil can alternatively have a plate structure with a buckle interface. The port of the coil includes a buckle and a port plate. The port plate has a plate 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 solutions in the second aspect and the technical effects brought by the technical solutions, please refer to the first aspect. Details will not be described again here.

Brief Description of the Drawings

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

[0034] [Figure 2] It is a diagram of the structure of a solar power generation inverter 20 according to an embodiment of the present application.

[0035] [Figure 3] This is a front view of a solar power inverter 20 according to one embodiment of this application.

[0036] [Figure 4] This is a side view of a solar power inverter 20 according to one embodiment of this application.

[0037] [Figure 5] Figure 3 shows a cross-sectional diagram of the solar power inverter 20.

[0038] [Figure 6] This is a side view of the shaft of a second power inductor according to one embodiment of this application.

[0039] [Figure 7] This is a side view of a second power inductor with a concealed inductor housing according to one embodiment of this application.

[0040] [Figure 8] This is a front view of a second power inductor with an inductor housing concealed, according to one embodiment of this application.

[0041] [Figure 9] This is a side view of an inductor cover plate according to one embodiment of the present application.

[0042] [Figure 10] This is a diagram showing the structure of a connecting bracket according to one embodiment of this application.

[0043] [Figure 11] This is a diagram illustrating the structure of the connection between a conductive metal strip and a coil end according to one embodiment of this application.

[0044] [Figure 12] This is a side view of the shaft of a first power inductor according to one embodiment of this application. [Modes for carrying out the invention]

[0045] The technical solution of this application will be described below with reference to the attached drawings.

[0046] In the embodiments of this application, prefixes such as “first,” “second,” and “third” are used solely to distinguish different described subjects and do not constitute any limitation regarding the location, order, priority, quantity, content, etc., of the described subjects. In the embodiments of this application, the use of prefixes used to distinguish described subjects, such as ordinal numbers, does not constitute a limitation of the described subjects. For a description of the described subjects, please refer to the claims or the contextual description in the embodiments. The use of such prefixes should not constitute a redundant limitation. Furthermore, in the description of embodiments, unless otherwise specified, “multiple” means two or more.

[0047] In embodiments of this application, orientations or positional relationships indicated by terms such as “top,” “bottom,” “left,” “right,” “front,” “rear,” “upper,” “bottom,” “inside,” and “outside” are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to illustrate and simplify this application, and do not indicate or imply that any particular device or element must have a particular orientation, or must be constructed and operated in a particular orientation, and therefore should not be understood as limitations of this application.

[0048] References to “several embodiments” etc. described herein indicate that one or more embodiments of this application include certain features, structures, or characteristics described by reference to those embodiments. Therefore, descriptions of “several embodiments” etc. appearing elsewhere in this specification do not necessarily refer to the same embodiments, but rather mean “one or more embodiments, but not all of them,” unless otherwise specifically emphasized. The terms “including,” “having,” and variations thereof all mean “including, but not limited to,” unless otherwise specifically emphasized.

[0049] In the embodiments of this application, the same reference numeral represents the same component or the same part or component. In the embodiments of this application, for multiple identical parts or components, only one of the parts or components may be used as an example to indicate the reference numeral in the accompanying drawings. The reference numeral is also applicable to other identical parts or components. Furthermore, the dimensions of the parts or components shown in the accompanying drawings are for illustrative purposes only.

[0050] To facilitate understanding, the relevant technical terms and English abbreviations used in the embodiments of this application are first explained below.

[0051] Solar power inverter: An inverter is a converter that converts direct current (DC) into constant frequency constant voltage alternating current (AC) or frequency-modulated voltage controlled AC. A solar power inverter is an inverter that converts the variable DC generated by solar panels (also called photovoltaic panels) into main-line frequency AC.

[0052] Power conversion system (PCS): A power conversion system can control the charging and discharging process of batteries, perform AC-DC conversion, and supply power directly to AC loads when there is no power grid.

[0053] Uninterruptible power supply (UPS): An uninterruptible power supply is a device connected between electronic equipment and a power supply unit, configured to prevent the electronic equipment from being shut off due to peak demand, current control, etc.

[0054] Parallelism: The term "parallelism" as used in this application is not limited to absolute parallelism. The definition of "parallelism" can be understood as basic parallelism. Absence of absolute parallelism is permitted due to the effects of assembly tolerances, design tolerances, structural flatness, or other factors.

[0055] Perpendicular: Perpendicular as defined in this application is not limited to absolute perpendicularity (angle of 90 degrees). Absence of absolute perpendicularity is permitted due to assembly tolerances, design tolerances, structural flatness, or other factors. Errors within small angular ranges are permitted. For example, an assembly error range of 80 to 100 degrees may be understood as perpendicular.

[0056] PV stands for photovoltaic, meaning that electricity is generated using solar energy. A PV port refers to a port connected to a solar power generation module.

[0057] Common-mode interference: Common-mode interference means that the amplitude of the interference voltage in a signal cable is the same as the amplitude of the interference voltage in the signal cable's return cable (commonly also called a signal ground cable). Here, the voltage uses a nearby object (ground, metal chassis, reference ground plane, etc.) as the reference potential. The interference current loop flows within a loop that includes the conductor and the reference object.

[0058] Creep effect: A slow, persistent deformation of a solid material under stress, resulting from long-term stress that is lower than the material's yield strength.

[0059] Embodiments of this application provide a cable-free inductor and the application of a cable-free inductor in a power converter.

[0060] The inductor includes an inductor housing, an inductor cover plate, a magnetic core, and a coil. The inductor housing and inductor cover plate are enclosed to form a housing space, the magnetic core and coil are located within the housing space, and the coil is wound around the magnetic core. The inductor cover plate includes a cover plate body and a connecting bracket. The cover plate body is plate-shaped and connects to an opening in the inductor housing. The connecting bracket is located on the 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] An 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 and bottom housings are enclosed to form a housing cavity, and the main circuit board is mounted in the housing cavity, with both the plane on which the main circuit board is located and the plane on which the upper housing is located being perpendicular to a first direction. The bottom housing includes a through hole. Along the first direction, the power inductor is connected to the main circuit board through the through hole.

[0062] The cable-free inductor provided in the embodiments of this application can be independently removed from the power converter. Therefore, the manufacturing processes of the cable-free inductor and the power converter do not interfere with each other, thus shortening the overall manufacturing time of the power converter. In addition, the cable-free inductor is directly connected to the circuit board, eliminating the need for cables. This eliminates the possibility of cable connection errors, simplifies the installation procedure of the power inductor, reduces the overall size of the power converter, and improves the process aesthetics of the power converter.

[0063] The cable-free inductors provided in embodiments of this application can be used in various power conversion devices that require power inductors. Power conversion devices including the cable-free inductors of this application can be used in application scenarios such as residential green power, industrial green power, and solar power plants. Power conversion devices include solar power inverters, power conversion systems (PCS), and uninterruptible power supplies (UPS).

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

[0065] Specifically, the solar power inverter 20 can convert direct current (DC) from the solar power modules 10 to alternating current (AC) and send that AC to the power grid 40 or load 50. The solar power inverter 20 can also send DC from the solar power modules 10 to the energy storage system 30 to charge the energy storage system 30. The energy flow between the solar power inverter 20 and the energy storage system 30, and between the solar power inverter 20 and the power grid 40, is bidirectional. In other words, the solar power inverter 20 can convert DC from the energy storage system 30 to AC and send that AC to the power grid 40 or load 50; the solar power inverter 20 can send AC from the power grid 40 to the load 50, or convert AC to DC and then send that DC to the energy storage system 30 for charging.

[0066] If the solar power generation system 1 includes a solar power generation module 10, a solar power generation inverter 20, and an energy storage system 30, the solar power generation inverter 20 is configured primarily to connect the solar power generation module 10 to the energy storage system 30 in order to charge the energy storage system 30. If the solar power generation system 1 includes a solar power generation module 10, a solar power generation inverter 20, an energy storage system 30, a power grid 40, and a load 50, the solar power generation inverter 20 can be configured to connect these devices. For example, the solar power generation inverter 20 connects the solar power generation module 10 to the energy storage system 30. The solar power generation inverter 20 connects the solar power generation module 10 to the power grid 40. The solar power generation inverter 20 connects the solar power generation module 10 to the load 50. The solar power generation 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 electrical energy. For example, the energy storage system 30 can store DC electrical energy from the photovoltaic power generation module 10, and the energy storage system 30 can use the photovoltaic power inverter 20 to supply power to the power grid 40 or load 50. Therefore, the application scenarios for the energy storage system 30 are wide-ranging and include, but are not limited to, residential scenarios, industrial green power scenarios, and smart solar power plant scenarios.

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

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

[0070] Power inductors are one of the main heat-generating components in power conversion devices (including the aforementioned solar cell inverters). In this case, when designing power inductors, it is necessary to consider the large heat dissipation requirements of the power inductor. To improve the heat dissipation capacity of power inductors in power conversion devices using natural heat dissipation, two methods are usually used. In Method 1, the power conversion device includes the entire mechanical structural member and the inductor cavity, and the inductor cavity can be removed independently from the entire mechanical structural member. The power inductor is potted in the inductor cavity using a potting compound with good thermal conductivity, and the power inductor has a cable that connects to the substrate of the entire mechanical structural member. To meet the requirements of IP65 protection level, a sealing rubber strip needs to be added to the joint between the inductor cavity and the entire mechanical structural member. In Method 2, the entire mechanical structural member and the inductor cavity are an integrated structure. The inductor cavity is located in a separately secured position within the entire mechanical structural member. The power inductor is potted in the inductor cavity, and the power inductor has a cable that connects to the substrate of the entire mechanical structural member.

[0071] However, each of the two methods has obvious problems. In Method 1, the inductor cavity is located outside the entire mechanical structural member, and the seal between the inductor cavity and the entire mechanical structural member must be performed by using a sealing rubber strip or by other sealing methods. In this case, additional sealing costs increase, seal reliability is low, and the overall size of the power converter increases. Also, the power inductor and the substrate are connected via cables. In this case, the process aesthetics of the device are poor, and there is a possibility of cable connection errors. In Method 2, space must be reserved for the inductor cavity within the entire mechanical structural member. In this case, the overall size of the power converter also increases. Also, cable connections detract from the process aesthetics of the device, and there is a possibility of cable connection errors. Furthermore, during the manufacture of the power converter, the power inductor and potting compound must first be potted inside the inductor cavity, and other elements in the power converter can only be assembled after the potting compound has completely solidified. Such a solidification process takes a considerable amount of time, significantly delaying the manufacturing period of the power converter.

[0072] However, in this application, the power inductor is potted in a separate inductor cavity, and the inductor cavity directly functions as part of the heat dissipation housing of the power converter. This ensures sufficient heat dissipation requirements for the power inductor and improves the sealing reliability of the power converter. In addition, the power inductor is directly connected to the substrate by pulling out a conductive metal strip. This eliminates the possibility of cable connection errors, simplifies the power inductor installation procedure, shortens the overall manufacturing time of the power converter, reduces the overall size of the power converter, and significantly improves the process aesthetics of the power converter.

[0073] The following describes in detail the cable-free inductor and the photovoltaic inverter 20 including the cable-free inductor provided in the embodiments of this application. It should be understood that the photovoltaic inverter 20 is merely an example. The cable-free inductor solution provided in the embodiments of this application is applicable to other power conversion products including power inductors.

[0074] Figure 2 is a diagram of the structure of a solar power inverter 20 according to one embodiment of this application. Figure 3 is a front view of the solar power inverter 20 according to one embodiment of this application. Figure 4 is a side view of the solar power inverter 20 according to one embodiment of this application. Figure 5 is a diagram of the cross-sectional structure of the solar power inverter 20 shown in Figure 3.

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

[0076] In this implementation, the upper housing 203 has a plate-like structure. The main circuit board 206 is arranged parallel to the upper housing 203. The bottom housing 204 has a groove-like structure. Because the main circuit board 206 is arranged in close proximity to the upper housing 203, the internal cavity S of the solar power inverter 20 is divided by the main circuit board 206 into a first cavity S1 and a second cavity S2. The first cavity S1 is a cavity formed between the upper housing 203 and the side of the main circuit board 206 that faces the upper housing 203. The second cavity S2 is a cavity formed between the bottom housing 204 and the side of the main circuit board 206 that faces the bottom housing 204. All of the main electrical elements of the solar power inverter 20 are mounted on the side of the main circuit board 206 that faces the bottom housing 204. These main electrical components, such as power modules or capacitors, are relatively large and have high heat dissipation requirements. Smaller electrical components with low heat dissipation requirements, such as signal indicators, surface-mount capacitors, and surface-mount resistors, are mounted on the side of the main circuit board 206 that faces the upper housing 203. Heat dissipation fins are located 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 heat dissipation capacity of the solar power inverter 20 is improved because components with high heat dissipation requirements are located near the bottom housing 204. Furthermore, the bottom housing 204 has a grooved structure, and the distance between the groove surface and the main circuit board 206 is determined by the height of the electrical components closest to the groove surface (the height of the electrical components in a direction perpendicular to the main circuit board 206). This minimizes the size of the second cavity S2. Since the main circuit board 206 is located close to the upper housing 203, the size of the first cavity S1 is minimized. Therefore, the overall size of the solar power inverter 20 can be minimized, and the heat dissipation requirements of the electrical elements are also ensured.

[0077] Conventional technologies that integrate power inductors into solar inverters cannot overcome the following problems. Specifically, in the manufacturing process of solar inverters, which includes the packaging process of the power inductor potting compound, the packaging of the power inductor potting compound usually involves a long potting compound solidification process. Multiple electrical elements within the solar inverter should only be assembled after the power inductor potting compound has completely solidified. In this case, the packaging process of the power inductor potting compound occupies a large portion of the entire manufacturing period of the solar inverter. As a result, the overall manufacturing period of the solar inverter is too long.

[0078] In this implementation, a reserved through-hole is provided in the bottom housing 204. 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-hole in the bottom housing 204. The housings of the first power inductor 201 and the second power inductor 202 can be attached to the bottom housing 204 using bolts and can be independently removed from and attached to the photovoltaic inverter 20. In the manufacturing process of the photovoltaic inverter 20, the first power inductor 201 and the second power inductor 202 may be manufactured, packaged and solidified separately in the factory, and then assembled into the photovoltaic inverter 20 after the manufacturing of the first power inductor 201 and the second power inductor 202 is complete. The manufacturing process of the first power inductor 201 and the second power inductor 202 does not affect the assembly process of other electrical elements of the photovoltaic inverter 20. Therefore, the total manufacturing time of the photovoltaic inverter 20 is significantly reduced.

[0079] Furthermore, heat dissipation fins are placed on the outer surfaces of the first power inductor 201 and the second power inductor 202. When the solar power inverter 20 is operating, the heat generated by the power inductors can also be dissipated 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 enclosed by being connected with bolts and sealed with a sealing ring (not shown in Figures 2 to 5) to form an internal cavity S. This also satisfies the sealing requirements of the solar power inverter 20. See Figure 5. The inductor coil and the inductor magnetic core are mounted inside the first power inductor 201 and the second power inductor 202. Pins drawn out by the inductor coil are directly fixed to the main circuit board 206 via copper rods. In this way, the first power inductor 201 and the second power inductor 202 are directly connected to the main circuit board 206, thus avoiding problems such as cable connection errors and complex installation that may occur due to cable connections. Furthermore, the first power inductor 201 or the second power inductor 202, the main circuit board 206, and the upper housing 203 are arranged sequentially in a direction perpendicular to the main circuit board 206. Compared to 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 significantly reduces the projected area of ​​the photovoltaic inverter in the direction perpendicular to the main circuit board 206, improving the compactness of the arrangement of electrical elements in the photovoltaic inverter 20. This promotes miniaturization and enhancement 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] The first power inductor 201 and the second power inductor 202 provided in the embodiments of this application will be described in detail below.

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

[0083] In one implementation, referring to Figure 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 enclosed to form a housing space S3. The housing space S3 houses the magnetic core and coil of the inductor (not shown in Figure 6). The inductor cover plate 2021 is removable from the inductor housing 2029, which is secured to the inductor cover plate via bolts. L202 are bolt holes reserved for mounting the bolts. In this implementation, two bolt holes L202 are located at the two diagonal ends of the inductor cover plate 2021, respectively. During factory manufacturing, the magnetic core and coil of the inductor are first placed in the housing space S3. In this placement process, the position of the inductor cover plate 2021 must coincide with that of the inductor housing. In other words, the positions of the two bolt holes L202 must correspond to the screw holes (not shown in Figure 6) secured in the inductor cover plate 2021. Bolts are then fastened through the two bolt holes L202 to ensure that the inductor housing 2029 and the inductor cover plate 2021 are fixed relative to each other. Potting compound is then potted into the housing space S3. After the potting compound has completely solidified, the second power inductor 202 can be assembled into the photovoltaic inverter 20.

[0084] In this implementation, the inductor housing 2029 includes heat sink fins 2027, a housing connector 2026, and positioning pins 2028. The majority of the outer surface of the inductor housing 2029 is designed to be heat sink fins. This helps to quickly and efficiently dissipate the heat generated by the power inductor within the inductor housing 2029, controlling the temperature of the photovoltaic inverter 20 to stay within an appropriate range and ensuring that the photovoltaic inverter 20 can operate normally for extended periods. During the operation process of the photovoltaic inverter, the power inductor continuously dissipates heat to the outside. The heat is first transferred to the potting compound. Through diffusion of the potting compound, the heat is transferred relatively evenly to the inner surface of the inductor housing 2029. After being transferred to the heat sink fins 2027 in the heat conduction process of the inductor housing 2029 material, the heat is rapidly released into the ambient environment. The housing connector 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 structure is configured to mount the magnetic core and coil of the power inductor. The housing connector 2026 and the heat dissipation fin 2027 are integral structures. The annular strip structure has a specific width and is designed on it with positioning pins 2028, screw holes L201, screw holes aligned with bolt through holes L202, and a seal ring groove 2030. There are two positioning pins 2028, each located on the opposite side of the housing connector, and are configured to position the second power inductor 202 during the process of mounting it to the photovoltaic inverter 20. There are four screw holes L201, two of each located on the opposite side of the housing connector, and are configured to be fastened between 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 connecting bracket 2024, and a cover plate body 2022. The cover plate body 2022 is a plate-like structure. The cover plate body 2022 has a coil through-hole so that the coil end 2031 can pass through the cover plate body 2022. The coil end 2031 is a terminal drawn out by the two ends of the coil 2034 (as shown in Figures 7 and 8), is a long strip plate-like structure, and is configured to provide an electrical connection to the main circuit board 206. To provide a cable-free electrical connection between the power inductor and the main circuit board 206, a solution combining the conductive metal strip 2023 and the connecting bracket 2024 is used in the embodiments of this 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 perpendicularly into the through-hole. The connection between the conductive metal strip 2023 and the coil end 2031 is secured by welding. A threaded hole is provided at the other end of the conductive metal strip 2023. The connecting bracket 2024 is a columnar structure and is integrated with the cover plate body 2022. A threaded hole is provided in the center of the connecting bracket 2024. During installation, the threaded hole, the threaded hole at the other end of the conductive metal strip 2023, and the threaded hole in the main circuit board 206 overlap each other, allowing bolts to pass through the main circuit board 206, the conductive metal strip 2023, and the connecting bracket 2024. In this implementation, the connecting bracket 2024 may have both the function of supporting the conductive metal strip 2023 and the function of housing the connecting components. See Figure 7 in particular. The bending angle of the Z-shaped structure of the conductive metal strip 2023 is acute. As a result, the conductive metal strip 2023 has a specific deformation space in the connection area perpendicular to the cover plate body 2022 and parallel to the coil end 2031, thus reducing the design tolerance requirements for the power inductor.The magnetic ring 2025 is formed in a sleeve-like manner on the outside of the coil end 2031, the conductive metal strip 2023, and the connecting 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, suppressing common-mode interference. The magnetic ring 2025 is connected to the cover plate body 2022 by adhesive bonding. In particular, fixing protrusions (not shown in Figure 6) are further positioned on the cover plate body 2022. The fixing protrusions and the cover plate body 2022 are integrally formed to provide positioning for the magnetic ring 2025 for mounting and restrict the movement of the magnetic ring 2025 along the surface of the cover plate body 2022. In another optional implementation, the magnetic ring 2025 may be positioned, restricted, and secured using buckles.

[0086] When the second power inductor 202 is attached to the photovoltaic inverter 20 after the potting compound has completely hardened, the seal ring, which is already positioned in the seal ring groove 2030, is first aligned with the corresponding positioning pin hole in the bottom housing 204 based on the positioning pin 2028, and then secured from the side of the bottom housing 204 through four screw holes L201 using bolts. The seal ring fills the gap between the inductor housing and the bottom housing 204 by fastening and compression with bolts, isolating the inside of the photovoltaic inverter 20 from the outside of the photovoltaic inverter 20. The connecting bracket is then secured to the main circuit board 206 using bolts, making a portion of the main circuit board 206 corresponding to the connecting bracket 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. Thus, a cable-free electrical connection is achieved between the second power inductor 202 and the main circuit board 206.

[0087] In one implementation, referring to Figures 7 and 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 has two coil ends 2031. The framework 2033 is partially fixed to the cover plate body 2022. The central portion of the framework 2033 is configured to house and fix the magnetic core 2032 and to isolate direct contact between the coils 2034 and the magnetic core. The coils 2034 are wound around the magnetic core 2032. It should be understood that the quantity of coils 2034, the form of the magnetic core 2032, and the quantity and manner of the coil ends 2031 drawn out by the coils 2034 may be adaptively modified based on the configuration of the circuit. This is not limited to the present application.

[0088] In the technical solutions provided in the aforementioned embodiments of this application, after the second power inductor 202 is fixed to the bottom housing 204 and the main circuit board 206 via bolts, in the first embodiment, since the coil end 2031 and the conductive metal strip 2023 are not integral structures, a relatively large force may be generated at the junction between the coil end 2031 and the conductive metal strip 2023. To improve the reliability of the connection between the coil end 2031 and the conductive metal strip 2023 and to further reduce design tolerance requirements, this application provides another embodiment of the inductor cover plate 2021. In the second embodiment, a creep effect may occur in the main circuit board 206. As a result, the contact resistance between the conductive metal strip 2023 and the main circuit board 206 increases, leading to poor contact between the two. When the solar power inverter is operating, the temperature at the junction between the two rises relatively rapidly. In severe cases, a fire may occur. To mitigate the effects of the creep effect on the main circuit board 206, this application provides another embodiment of the inductor cover plate 2021.

[0089] Figure 9 is an axial diagram of an inductor cover plate according to one embodiment of this application. Figure 10 is a diagram of the structure of a connecting bracket according to one embodiment of this application. Figure 11 is a diagram of the connection structure between a conductive metal strip and a coil end according to one embodiment of this application.

[0090] In one implementation, referring to Figure 9, the inductor cover plate 2021 includes a magnetic ring 2025, a conductive metal strip 2023, a connecting bracket 2024, and a cover plate body 2022. The relative positional relationship between the magnetic ring 2025, the conductive metal strip 2023, the connecting bracket 2024, and the cover plate body 2022, as well as the structural configuration of the magnetic ring 2025 and the cover plate body 2022, are the same as those of the embodiment shown in Figure 6. For the sake of brevity, the details will not be 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 connecting bracket 2024, this implementation provides a structural design for aligning the conductive metal strip 2023 and the connecting bracket 2024. In the second embodiment, 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 for the bent portion of the conductive metal strip 2023. In a third embodiment, to improve the reliability of the connection between the coil end 2031 and the conductive metal strip 2023, this implementation provides a structural design for the connection between the conductive metal strip 2023 and the coil end.

[0091] The three structural designs will be described in detail below, with reference to the attached drawings.

[0092] Refer to Figure 10. The connecting bracket 2024 includes a nut groove 20242 and a fixed sidewall 20241. The nut groove 20242 is located in the hollow portion of the connecting bracket 2024 that is close to the main circuit board 206. The nut groove 20242 is configured to accommodate a nut and, in cooperation with a bolt, enables a fastening connection between the connecting bracket 2024, the conductive metal strip 2023, and the main circuit board 206. In one implementation, a flange nut may be placed 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 does not deform over time. The fixed sidewall 20241 is located at the upper end of the connecting bracket 2024, which is the upper end that connects to the conductive metal strip 2023. The main part of the fixed sidewall 20241 is located on three of the four sides of the rectangular upper end of the connecting bracket 2024, and the fixed sidewall and the connecting bracket 2024 are formed integrally. The fixed sidewall 20241 further includes a notched sidewall 20241A. The notched sidewall 20241A is located on the sides of the rectangle other than three of the four sides. The length of the notched sidewall 20241A occupies only a small portion of the length of the side on which the fixed sidewall 20241 is located. In this case, the notched sidewall 20241A surrounds the area so as to form a groove with a notch. After the conductive metal strip 2023 is embedded in the groove, the presence of the fixed sidewall 20241 restricts the movement of the conductive metal strip 2023 on the plane parallel to the main circuit board 206. Due to the presence of the fixed sidewall 20241, the work of positioning the connecting bracket 2024 by the conductive metal strip 2023 is facilitated, and the installation process can be simplified. In addition, the connection between the conductive metal strip 2023 and the connecting bracket 2024 is more reliable.

[0093] Refer to Figure 11. The conductive metal strip 2023 includes a bend notch 20231 and a bolt connection 20232. Referring to Figure 7, the conductive metal strip 2023 has a Z-shaped structure. Two bend notches 20231 are provided on the bend of the conductive metal strip 2023 that is close to the main circuit board 206. The presence of these bend notches 20231 can significantly improve the deformability of the bend where the bend notches 20231 are located. In one implementation of this application, the bend of the conductive metal strip that includes the bend notches 20231 can be deformed perpendicular to the plane on which the main circuit board is located, so that the conductive metal strip 2023 always maintains contact with the main circuit board 206. Thus, excessively large contact resistance at the junction 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 embedded portion 20232A matches the shape of the notch sidewall 20241A. When the conductive metal strip 2023 is fixed to the connecting bracket 2024, the embedded portion 20232A and the notch sidewall 20241A are connected to each other.

[0094] See also Figure 11. 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 Figure 11), and the other end of the port plate 20312 branches from the center to form two buckles 20311. In this implementation of the present application, the two buckles 20311 are each bent in two opposite directions, 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. Thus, 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., 3) and the bending direction of the buckles 20311 (e.g., two buckles bending in the same direction) may vary. This is not limited to the present invention.

[0095] Figure 12 is an axial view of a first power inductor according to one embodiment of this application.

[0096] In one implementation, the first power inductor 201 includes an inductor housing 2029 (not shown in Figure 12) and an inductor cover plate 2021. The inductor cover plate 2021 includes a cover plate body 2022, connection brackets 2024, and conductive metal strips 2023. For brevity, the first power inductor 201 has a similar structure to the second power inductor 202. Details will not be described again here. The difference is that the first power inductor is a boost circuit inductor and has three MPPT inputs, so the first power inductor 201 includes three coils (not shown in Figure 12). The three coils lead to 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 located in different circuits, the first power inductor 201 does not include a magnetic ring.

[0097] In actual application processes, the number of power inductors may be changed based on different circuit structures of the solar power inverter. Alternatively, the number of coils in the power inductor and the specific structural configuration of the cover plate body may be adaptively changed based on different functions of the power inductors in the circuit and different specifications of the power inductors. It should be understood that the above changes do not exceed the scope of protection of this application.

[0098] The photovoltaic inverter and cable-free power inductor provided in the embodiments of this application are described in detail above. The principles and embodiments of this application are described herein using specific examples. The above description of embodiments is provided solely to aid in understanding the methods and core ideas of this application. Furthermore, those skilled in the art can modify and adapt the ideas of this application with respect to specific embodiments and scopes.

[0099] The above description represents only specific embodiments of this application and is not intended to limit the scope of protection of this application. Modifications or substitutions readily understood by those skilled in the art within the scope of the technical scope disclosed herein are included in the scope of protection of this application. Accordingly, the scope of protection of this 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 lower housing are enclosed to form a housing cavity, the main circuit board is mounted within the housing cavity, and the surface on which the main circuit board is located is parallel to the surface on which the upper housing is located. The bottom housing has a through hole through which the power inductor passes through the bottom housing along a first direction and is connected to the main circuit board, the first direction being perpendicular to the surface on which the main circuit board is located. The power inductor comprises an inductor housing, an inductor cover plate, a magnetic core, and a coil, wherein the inductor housing and the inductor cover plate are enclosed to form a housing space, the magnetic core and the coil are located within the housing space, and the coil is wound around the magnetic core. The inductor cover plate has a connecting bracket, the connecting bracket is located on the side of the inductor cover plate away from the coil, and the connecting bracket is configured to support conductive components between the power inductor and the main circuit board. The inductor cover plate has a coil through-hole and a conductive metal strip, the coil passes through the coil through-hole and through the inductor cover plate, one end of the conductive metal strip is connected to the main circuit board, 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 inductor cover plate has a magnetic ring, the magnetic ring is fixed to the inductor cover plate, the magnetic ring is positioned around the connecting bracket, and the power line formed by connecting the conductive metal strip and the coil passes through the magnetic ring. Inverter.

2. The connecting bracket has a hollow structure, the hollow structure is provided with a nut groove, a nut is placed in the nut groove, one end of the main circuit board and the 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 via the conductive metal strip. The inverter according to claim 1.

3. The connecting bracket has a prism structure, and fixed side walls are provided on the peripheral edge of the connecting bracket that is close to the surface of the main circuit board, and the fixed side walls have a projection structure with notches, and the fixed side walls are distributed on three sides of the peripheral edge, and the fixed side walls are distributed on a part of the other side of the peripheral edge. The inverter according to claim 2.

4. The conductive metal strip has a Z-shaped plate structure, the port of the coil has a plate 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 1.

5. The conductive metal strip has a Z-shaped plate structure, and the port of the coil has a buckle and a port plate, the port plate has a plate 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 that faces the main circuit board. The inverter according to claim 1.

6. The conductive metal strip having a Z-shaped plate structure has two bent portions, and at least one of the two bent portions is provided with a bent portion notch. The inverter according to claim 4 or 5.

7. The power inductor has a seal groove and a seal ring, the seal groove is provided around one side of the inductor housing that is close to the inductor cover plate, 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 inverter according to claim 1.

8. The power inductor has a potting compound, the potting compound is potted within the housing space, and the potting compound is configured to immerse the magnetic core and the coil. The inverter according to claim 1.

9. The heat dissipation fins are arranged on the outer surfaces of both the bottom housing and the inductor housing. The inverter according to claim 1.

10. 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 bolts. The inverter according to claim 1.

11. The inductor housing is firmly connected to the bottom housing via bolts. The inverter according to claim 1.

12. An inductor device, The inductor device comprises an inductor housing, an inductor cover plate, a magnetic core, and a coil, wherein the inductor housing and the inductor cover plate are enclosed to form a housing space, the magnetic core and the coil are located within the housing space, and the coil is wound around the magnetic core. The inductor cover plate has a connecting bracket, the connecting bracket is located on the side of the inductor cover plate away from the coil, and the connecting bracket is configured to support conductive components between the inductor device and the circuit board. The inductor cover plate has a coil through-hole and a conductive metal strip, the coil passes through the coil through-hole and through the inductor cover plate, one end of the conductive metal strip is connected to the circuit board, the other end of the conductive metal strip is connected to the coil, and the inductor device is electrically connected to the circuit board via the conductive metal strip. The inductor cover plate has a magnetic ring, the magnetic ring is fixed to the inductor cover plate, the magnetic ring is positioned around the connecting bracket, and the power line formed by connecting the conductive metal strip and the coil passes through the magnetic ring. Inductor device.

13. The connecting bracket has a hollow structure, the hollow structure is provided with a nut groove, a nut is placed in the nut groove, one end of the conductive metal strip has 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 inductor device is firmly connected to the circuit board via the conductive metal strip. The inductor device according to claim 12.

14. 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 inductor device according to claim 12.

15. The conductive metal strip has a Z-shaped plate structure, and the port of the coil has a buckle and a port plate, the port plate has a plate 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 that faces the circuit board. The inductor device according to claim 12.

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