Inductor, power converter, and power conversion system

Abstract

The present application discloses an inductor, a power converter, and a power conversion system. The inductor comprises an inductor body and a flange structure; the flange structure comprises a flange frame and a non-metal connecting piece; the flange frame is configured to be connected to a first cavity; the non-metal connecting piece is fixed on the flange frame; and the inductor body is fixed at the end of the non-metal connecting piece facing away from the flange frame. According to the present application, the non-metal connecting piece is fixed on the flange frame, so that the flange structure has enough strength to fix the inductor body, and a metal heat dissipation housing and a potting adhesive do not need to be provided, thereby reducing the cost of inductor, and reducing the weight of the inductor.

Description

Inductor, power converter and power conversion system

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on March 29, 2024, with application number 202410374680.7 and invention name “An inductor, power converter and power conversion system”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the technical field of power converters, and in particular to an inductor, a power converter, and a power conversion system. Background Art

[0003] Inductors are important components that perform functions such as energy transmission, storage, and filtering. Existing inductors utilize a cast-in-shell structure, where the inductor body is encapsulated within a metal heatsink housing using potting compound to insulate it from the heatsink and then sealed and secured to the cavity. The metal heatsink housing and potting compound increase the inductor's weight and cost.

[0004] Summary of the Invention

[0005] In view of this, a first object of the present application is to provide an inductor to reduce the weight and cost of the inductor.

[0006] A second object of the present application is to provide a power converter.

[0007] The third object of this application is to provide a power conversion system.

[0008] In order to achieve the above first purpose, this application provides the following solutions:

[0009] An inductor comprising:

[0010] Inductor body;

[0011] The flange structure includes a flange frame and a non-metallic connector. The flange frame is used to connect the first cavity. The non-metallic connector is fixed on the flange frame. The inductor body is fixed on one end of the non-metallic connector away from the flange frame.

[0012] In a specific embodiment, the inductor body includes:

[0013] an insulating frame fixed to the non-metallic connecting piece;

[0014] The iron core and the winding are respectively arranged on the insulating frame, and the iron core and the winding are insulated.

[0015] In another specific embodiment, the insulating skeleton includes a first skeleton and a second skeleton;

[0016] The first frame and the second frame each have a receiving cavity for receiving the iron core;

[0017] The first frame and the second frame are respectively fixed on the non-metallic connecting member and are arranged to be inserted into each other. The winding is sleeved outside the inserting portion formed by the inserting of the first frame and the second frame.

[0018] In another specific embodiment, the first skeleton and the second skeleton are respectively clamped on the non-metallic connecting member.

[0019] In another specific embodiment, one of the first frame and the non-metallic connector is provided with a first engaging groove, and the other is provided with a first engaging protrusion engaged with the first engaging groove;

[0020] And / or, a second engaging groove is defined on one of the second frame and the non-metallic connecting member, and a second engaging protrusion engaged with the second engaging groove is provided on the other.

[0021] In another specific embodiment, the first clamping slot and / or the second clamping slot is a clamping slot structure with one end open and the other end closed.

[0022] In another specific embodiment, the inductor body further includes a locking structure;

[0023] The locking structure is used to lock the first frame and the second frame to the non-metallic connecting member.

[0024] In another specific embodiment, the locking structure includes a locking fastener, and the first frame and the second frame are respectively fastened to the flange structure through the locking fastener;

[0025] And / or, the locking structure includes a tightening member; along the insertion direction perpendicular to the first frame and the second frame, the first frame and the second frame are respectively constrained to the flange structure by the tightening member; and / or, along the insertion direction of the first frame and the second frame, the tightening member spans the first frame and the second frame to constrain the first frame and the second frame to the flange structure.

[0026] In another specific embodiment, at least one of the locking fasteners passes through the accommodating cavity and limits the iron core;

[0027] And / or, at least one of the locking fasteners passes through the accommodating cavity and the iron core respectively.

[0028] In another specific embodiment, the tightening member includes an insulating tape and a tightening metal tape, the two ends of the tightening metal tape are respectively connected to the flange structure, and are used to restrain the first frame and / or the second frame, and the non-metallic connector is sleeved outside the tightening metal tape and contacts the first frame and / or the second frame, thereby isolating and insulating the tightening metal tape from the first frame and / or the second frame;

[0029] And / or, the tightening member includes an end plate and a tensioning member, the end plate is connected to the non-metallic connecting member or passes through the non-metallic member and is connected to the flange frame; along the plug-in direction of the first frame and the second frame, at least one end plate is placed at one end of the insulating frame, and at least one end plate is placed at the other end of the insulating frame, one end of the tensioning member tensions at least one end plate at one end of the insulating frame, and the other end tensions at least one end plate at the other end of the insulating frame; and / or, along the plug-in direction perpendicular to the first frame and the second frame, at least one end plate is placed At one end of the first skeleton, at least one end plate is placed at the other end of the first skeleton, one end of the tensioning member tensions at least one end plate at one end of the first skeleton, and the other end tensions at least one end plate at the other end of the first skeleton; and / or, along the insertion direction perpendicular to the first skeleton and the second skeleton, at least one end plate is placed at one end of the second skeleton, at least one end plate is placed at the other end of the second skeleton, one end of the tensioning member tensions at least one end plate at one end of the second skeleton, and the other end tensions at least one end plate at the other end of the second skeleton.

[0030] In another specific embodiment, the end plate is provided with a limiting bending portion that abuts against the top of the first frame or the second frame in a limited position;

[0031] and / or,

[0032] The end plate is provided with a threaded hole, through which a fastener passes and abuts against the first frame or the second frame.

[0033] In another specific embodiment, the first frame and the second frame both include a frame yoke column and a frame center column;

[0034] The frame center column is fixed to the frame yoke column and communicates with the inner cavity of the frame center column. The core yoke column of the iron core is accommodated in the frame yoke column, and the core center column of the iron core is accommodated in the frame center column.

[0035] The skeleton center column of the first skeleton and the skeleton center column of the second skeleton are inserted into each other to form the inserting portion.

[0036] In another specific embodiment, the iron core is completely contained in the containing cavity.

[0037] In another specific embodiment, the first frame and the second frame are respectively provided with locking members for locking the iron core.

[0038] In another specific embodiment, a portion of the core extends outside the accommodating cavity;

[0039] The locking member includes a buckle, and the buckle is used to clamp the end surface of the iron core extending outside the accommodating cavity.

[0040] In another specific embodiment, the inductor body further includes a locking device for locking the first frame and the second frame.

[0041] In another specific embodiment, the locking device includes a hook and a slot;

[0042] One of the first frame and the second frame is provided with the hook, and the other is provided with a slot;

[0043] When the first frame and the second frame are inserted into place, the hook is engaged with the slot.

[0044] In another specific embodiment, the non-metallic connector is provided with a wire hole for allowing the wiring bar of the inductor body to pass through, and the wire hole and the wiring bar are sealed by a sealant.

[0045] In another specific embodiment, the end of the non-metallic connector facing the flange frame is provided with a wire outlet cavity arranged around the wire outlet hole;

[0046] Both ends of the outlet cavity are open, one end is connected to the outlet hole, and the other end is used to face the first cavity. The wiring block can pass through the outlet cavity and extend into the first cavity.

[0047] In another specific embodiment, the flange frame is provided with a connecting piece for connecting with the first cavity;

[0048] A sealing groove is formed at one end of the flange frame away from the non-metallic connector. A sealing ring is installed in the sealing groove. The sealing ring is arranged around the connector and is in sealing contact with the cavity wall of the first cavity.

[0049] In another specific embodiment, the connecting member includes: a connecting fastener threadedly connected to the flange frame, and / or a bolt fastener connected to the flange frame, and / or a plug connector connected to the flange frame.

[0050] In another specific embodiment, the inductor further includes a protective layer covering the inductor body to the flange structure.

[0051] In another specific embodiment, the inductor can be accommodated in a second cavity, and the protection of the first cavity is higher than that of the second cavity.

[0052] The various embodiments of the present application can be arbitrarily combined as needed. The embodiments obtained after these combinations are also within the scope of the present application and are part of the specific implementation methods of the present application.

[0053] The inductor provided by the present application realizes an insulated connection with the flange structure by fixing the inductor body on the non-metallic connector of the flange structure, and realizes a connection with the first cavity through the flange frame of the flange structure. The provision of the non-metallic connector realizes an insulated connection with the first cavity, ensures the insulation performance of the inductor body, and the inductor body can directly dissipate heat, thereby improving the heat dissipation efficiency and avoiding affecting the maximum operating temperature of the power inductor. The present application fixes the non-metallic connector on the flange frame so that the flange structure has sufficient strength to fix the inductor body, and there is no need to set a metal heat dissipation shell and potting glue, thereby reducing the cost of the inductor and reducing the weight of the inductor.

[0054] In order to achieve the above second purpose, this application provides the following solution:

[0055] A power converter comprises the inductor as described in any one of the above.

[0056] Since the power converter provided in the present application includes any one of the above-mentioned inductors, the beneficial effects of the above-mentioned inductors are all included in the power converter disclosed in the present application.

[0057] In order to achieve the third objective above, this application provides the following solutions:

[0058] A power conversion system includes the power converter as described above or the inductor as described in any one of the above.

[0059] Since the power conversion system provided in the present application includes the power converter described above or the inductor in any one of the above items, the beneficial effects of the above power converter or the above inductor are all included in the power conversion system disclosed in the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0061] FIG1 is a schematic diagram of a three-dimensional structure of an inductor provided in a first embodiment of the present application in one angular direction;

[0062] FIG2 is a schematic diagram of the three-dimensional structure of the inductor provided by the first embodiment of the present application in another angular direction;

[0063] FIG3 is a schematic diagram of the three-dimensional structure of the flange structure provided in this application;

[0064] FIG4 is a schematic diagram of the exploded structure of the flange structure provided in this application;

[0065] FIG5 is a schematic diagram of a three-dimensional structure of an inductor provided in a second embodiment of the present application;

[0066] FIG6 is a schematic diagram of the three-dimensional structure of the inductor provided in the first embodiment of the present application at another angle;

[0067] FIG7 is a schematic diagram of a three-dimensional structure of an inductor provided in a third embodiment of the present application;

[0068] FIG8 is a schematic diagram of the three-dimensional structure of the inductor body provided in this application;

[0069] FIG9 is a schematic diagram of the three-dimensional structure of the insulating frame provided in the first embodiment of the present application;

[0070] FIG10 is a schematic diagram of the exploded structure of the insulating frame provided in the first embodiment of the present application;

[0071] FIG11 is a schematic diagram of the three-dimensional structure of the iron core provided by the present application when it is to be assembled;

[0072] FIG12 is a schematic diagram of the three-dimensional structure of the insulating frame provided in the fourth embodiment of the present application;

[0073] FIG13 is a schematic structural diagram of a first skeleton provided in the first embodiment of the present application;

[0074] FIG14 is a schematic diagram of a three-dimensional structure of an iron core installed in an insulating frame according to a fifth embodiment of the present application;

[0075] FIG15 is a schematic diagram of the three-dimensional structure of the insulating frame provided in the sixth embodiment of the present application;

[0076] FIG16 is a schematic diagram of a three-dimensional structure of an inductor provided in a seventh embodiment of the present application;

[0077] FIG17 is a schematic diagram of a three-dimensional structure of an inductor provided in an eighth embodiment of the present application;

[0078] FIG18 is a schematic diagram of a three-dimensional structure of an inductor provided in a ninth embodiment of the present application;

[0079] FIG19 is a schematic diagram of a three-dimensional structure of an inductor provided in a tenth embodiment of the present application;

[0080] FIG20 is a schematic diagram of a three-dimensional structure of an inductor provided in the eleventh embodiment of the present application;

[0081] FIG21 is a schematic diagram of a three-dimensional structure of the connection between the end plate and the flange frame provided in the eleventh embodiment of the present application;

[0082] FIG22 is a schematic diagram of a three-dimensional structure of an inductor provided in a twelfth embodiment of the present application;

[0083] FIG23 is a schematic diagram of the inverter provided in this application.

[0084] Among them, in Figures 1 to 23: inverter 1000, inductor 100, inductor body 101, insulating frame 101-1, inner window 101-1a, first frame 101-1-1, first clamping protrusion 101-1-1a, second frame 101-1-2, second clamping protrusion 101-1-2a, frame yoke column 101-1-3, frame center column 101-1-4, buckle 101-1-5, iron core 101-2, winding 101-3, terminal block 101-3a, locking fastener 101-4, tightening member 101-5, insulating tape 101-5a, tightening metal tape 101-5b, end plate 101-5c, tensioning member 101-5d, hook 101-6, card slot 101-7, flange structure 102, flange frame 102-1, reinforcement rib 102-1a, mounting hole seat 102-1b, non-metallic connector 102-2, first card slot 102-2a, second card slot 102-2b, iron core yoke column 101-2-1, iron core middle column 101-2-2, wire outlet hole 102a, wire outlet cavity 102b, connector 102-3, sealing ring 102-4, protective layer 103, DC / DC circuit 200, DC / AC circuit 300. DETAILED DESCRIPTION

[0085] The following will be combined with Figures 1-23 of the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0086] In combination with Figures 1 to 23, the first aspect of the present application provides an inductor 100. As shown in Figures 1 and 2, the inductor 100 includes an inductor body 101 and a flange structure 102. The inductor body 101 is fixed on the flange structure 102, and the flange structure 102 is used to connect to the first cavity to be connected.

[0087] It should be noted that the inductor 100 can be entirely placed outside the first cavity and sealed to the first cavity. Alternatively, the inductor 100 can be entirely placed inside the first cavity and sealed to the first cavity. This article uses the example of the inductor 100 being entirely placed outside the first cavity. It is understood that the installation method for the inductor 100 inside the first cavity is similar to that for the inductor 100 outside the first cavity.

[0088] Specifically, referring to FIG. 3 and FIG. 4 , the flange structure 102 includes a flange frame 102 - 1 and a non-metallic connector 102 - 2 , and the flange frame 102 - 1 is connected to the first cavity.

[0089] It should be noted that flange frame 102-1 is made of a non-magnetic material with a certain strength and rigidity. It can be a metal material such as aluminum or aluminum alloy, or a non-metallic material with sufficient strength and rigidity, such as fiberglass reinforced plastic. In this embodiment, flange frame 102-1 is made of metal as an example. As shown in Figure 4, flange frame 102-1 is a hollow frame structure. Its shape and size are determined by the inductor body 101, and its thickness is designed to meet product strength requirements.

[0090] The non-metallic connector 102-2 is fixed to the flange frame 102-1. It should be noted that the method of fixing the non-metallic connector 102-2 to the flange frame 102-1 is not limited. The non-metallic connector 102-2 can be integrally formed by injection molding onto the flange frame 102-1, or it can be die-cast, etc. Of course, other fasteners can also be used for detachable connection. As long as the method of fixing the non-metallic connector 102-2 to the flange frame 102-1 is satisfied, it falls within the scope of protection of this application.

[0091] The flange frame 102-1 is provided with a connector 102-3 connected to the cavity wall of the first cavity. It should be noted that the flange frame 102-1 can be detachably connected to the cavity wall of the first cavity or can be non-detachably connected. When the flange frame 102-1 is detachably connected to the cavity wall of the first cavity, the connector 102-3 includes: a connecting fastener threadedly connected to the flange frame 102-1, the connecting fastener can be a bolt or a screw, etc., as shown in Figure 5; and / or, a threaded fastener connected to the flange frame 102-1, the threaded fastener can be a stud integrally connected to the flange frame 102-1, etc., as shown in Figure 6; and / or, a plug connector connected to the flange frame 102-1, the plug connector can be a quick-connect plug integrally connected to the flange frame 102-1, etc., as shown in Figure 7. When the flange frame 102-1 is non-detachably connected to the cavity wall of the first cavity, the connector 102-3 can specifically be an anchor nail or a welding layer, etc.

[0092] A sealing groove is provided at one end of the flange frame 102-1 facing away from the non-metallic connector 102-2, and a sealing ring 102-4 is installed in the sealing groove. The sealing ring 102-4 is arranged around the connector 102-3 and is in sealed contact with the wall of the first cavity. The flange frame 102-1 is sealedly connected to the first cavity through the sealing ring 102-4, thereby improving the protection of the first cavity. In addition, the sealing ring 102-4 is arranged around the connector 102-3. The pressure generated by the connector 102-3 connecting to the first cavity compresses the sealing ring 102-4, so that the sealing ring 102-4 is firmly in contact with the wall of the first cavity, thereby achieving a seal. This avoids the problem of a gap at the connection between the connector 102-3 and the first cavity, which affects the sealing effect, caused by the connector 102-3 being arranged outside the sealing ring 102-4. Specifically, the sealing ring 102-4 can be formed in the sealing groove by adhesive sealing strips or dispensing sealant.

[0093] To improve the strength of the flange frame 102-1 at the connection to the connector 102-3, a specific embodiment of the present application discloses that the flange frame 102-1 is provided with a mounting hole seat 102-1b at the location where the flange frame 102-1 connects to the connector 102-3. As shown in FIG4 , the number of mounting hole seats 102-1b is equal to the number of connectors 102-3, and they are arranged in a one-to-one correspondence. The mounting hole seats 102-1b extend toward the end near the non-metallic connector 102-2. On the one hand, this increases the mechanical strength of the connection to the connector 102-3. On the other hand, a positioning groove that mates with the mounting hole seat 102-1b can be provided at the corresponding position of the non-metallic connector 102-2, thereby increasing the bonding strength between the non-metallic connector 102-2 and the flange frame 102-1. When the connector 102-3 includes a connecting fastener threadedly connected to the flange frame 102-1, the mounting hole seat 102-1b undoubtedly also increases the effective locking depth of the threaded hole of the connector 102-3. The flange frame 102 - 1 is further provided with at least one circle of reinforcing ribs 102 - 1 a to increase the deformation resistance of the flange frame 102 - 1 , thereby improving the adhesion between the flange frame 102 - 1 and the non-metallic connector 102 - 2 .

[0094] As shown in Figure 3, the non-metallic connector 102-2 completely covers the end of the flange frame 102-1 facing the non-metallic connector 102-2, as well as the circumferential side edges of the non-metallic connector 102-2. This structure insulates the non-metallic frame from the energized high-voltage winding 101-3 on the inductor body 101. When the inductor 100 is located outside the first cavity, it also reduces the amount of inductor heat conducted into the first cavity. Specifically, the non-metallic frame can be made of non-metallic materials such as epoxy and plastic, or other types of non-metallic materials. The thickness of the non-metallic frame is designed based on insulation withstand voltage and mechanical strength.

[0095] In order to improve the connection stability between the non-metallic connector 102-2 and the flange frame 102-1 and to achieve sealing between the two, a specific embodiment of the present application discloses that the flange frame 102-1 and the non-metallic connector 102-2 are connected by an integral casting process. It can be understood that the use of an integral casting process to connect the flange frame 102-1 and the non-metallic connector 102-2 is only a specific embodiment of the present application. In actual applications, the flange frame 102-1 and the non-metallic connector 102-2 can also be connected by other connection methods, for example, the flange frame 102-1 and the metal connector are detachably fastened with fasteners and sealed with sealants. The present application fixes the non-metallic connector 102-2 to the flange frame 102-1, so that the flange structure 102 has sufficient insulation strength to fix the inductor body 101, and there is no need to set up a metal heat dissipation shell and potting glue, thereby reducing the cost of the inductor 100 and reducing the weight of the inductor 100.

[0096] The inductor body 101 is fixed to the end of the non-metallic connector 102-2 facing away from the flange frame 102-1. The non-metallic connector 102-2 provides insulation isolation from the first cavity, ensuring the insulation performance of the inductor body 101. This allows the inductor body 101 to dissipate heat directly, improving heat dissipation efficiency and preventing it from affecting the maximum operating temperature of the power inductor. Furthermore, it provides a sealed barrier between the inductor body 101 and the first cavity, eliminating the need for additional sealing gaskets or adhesive, further reducing the cost of the inductor 100.

[0097] In this embodiment, the terminal block 101 - 3 a on the inductor body 101 passes through the non-metallic connector 102 - 2 in a sealed manner and extends into the first cavity to achieve connection with the electrical device in the first cavity.

[0098] In some embodiments, as shown in FIG8 , the inductor body 101 includes an insulating frame 101-1, an iron core 101-2, and a winding 101-3. The insulating frame 101-1 is fixed to a non-metallic connector 102-2, and the specific connection method is not limited. The insulating frame 101-1 is made of a non-metallic insulating material and is primarily used as a mechanical structural fixture and primary insulation for the winding 101-3 and the iron core 101-2. It should be noted that the shape of the insulating frame 101-1 is not limited and can be configured to any shape and structure that can accommodate the iron core 101-2 and the winding 101-3.

[0099] The iron core 101-2 and the winding 101-3 are respectively mounted on the insulating frame 101-1, and the iron core 101-2 and the winding 101-3 are insulated to prevent the winding 101-3 from failing due to insulation breakdown of the iron core 101-2.

[0100] In some embodiments, as shown in FIG9 , the insulating frame 101-1 includes a first frame 101-1-1 and a second frame 101-1-2. The first frame 101-1-1 and the second frame 101-1-2 each have a receiving cavity for accommodating the iron core 101-2, as shown in FIG11 . The iron core 101-2 is placed in the receiving cavity, so that the insulating frame 101-1 provides effective mechanical protection for the iron core 101-2, preventing it from cracking due to external mechanical forces or rusting due to external humid environmental factors.

[0101] The first frame 101-1-1 and the second frame 101-1-2 are respectively fixed to the non-metallic connector 102-2. Specifically, the first frame 101-1-1 can be clamped to the non-metallic connector 102-2, or can be detachably connected to the non-metallic connector 102-2 via fasteners, or can be riveted to the non-metallic connector 102-2 via anchors, etc. Similarly, the second frame 101-1-2 can be clamped to the non-metallic connector 102-2, or can be detachably connected to the non-metallic connector 102-2 via fasteners, etc., or can be riveted to the non-metallic connector 102-2 via anchors, etc.

[0102] The first frame 101-1-1 and the second frame 101-1-2 are arranged to be inserted into each other, and the winding 101-3 is mounted outside the insertion portion formed by the insertion of the first frame 101-1-1 and the second frame 101-1-2. The arrangement of the accommodating cavity and the insertion portion ensures insulation between the core 101-2 and the winding 101-3, preventing insulation breakdown failure of the winding 101-3 on the core 101-2.

[0103] As shown in FIG10 , a specific embodiment of the present application discloses that both the first skeleton 101-1-1 and the second skeleton 101-1-2 include a skeleton yoke column 101-1-3 and a skeleton center column 101-1-4, wherein the skeleton center column 101-1-4 is fixed to the skeleton yoke column 101-1-3 and communicates with the inner cavity of the skeleton center column 101-1-4. It should be noted that the skeleton center column 101-1-4 and the skeleton yoke column 101-1-3 are both hollow columnar structures with open ends. The core yoke column 101-2-1 of the iron core 101-2 is accommodated within the skeleton yoke column 101-1-3, and the core center column 101-2-2 of the iron core 101-2 is accommodated within the skeleton center column 101-1-4.

[0104] The skeleton center column 101-1-4 of the first skeleton 101-1-1 and the skeleton center column 101-1-4 of the second skeleton 101-1-2 are inserted into each other to form an inserting portion.

[0105] It should be noted that, in the first skeleton 101-1-1 or the second skeleton 101-1-2, the number of the skeleton center columns 101-1-4 is not limited. As shown in FIG10 , the number of the skeleton center columns 101-1-4 is two, which are spaced apart on the skeleton yoke column 101-1-3. It should be noted that the number of the skeleton center columns 101-1-4 is not limited to two, and can also be set to three or more. The shapes of the skeleton center columns 101-1-4 can be the same or different. For example, as shown in FIG12 , the number of the skeleton center columns 101-1-4 on the first skeleton 101-1-1 and the second skeleton 101-1-2 are both three, and in the same first skeleton 101-1-1 or second skeleton 101-1-2, the two skeleton center columns 101-1-4 have the same shape, both of which are cylindrical; and the shape of one skeleton center column 101-1-4 is different, which is a square cylinder. At this time, the square cylindrical skeleton center column 101-1-4 can be used as a guide device instead of placing the core yoke column 101-2-1. At the same time, the bending resistance of the skeleton yoke column 101-1-3 is also improved. Of course, it is also possible to place the core yoke column 101-2-1 in at least one of the skeleton center columns 101-1-4 to form different types of inductor core structures, for example, a two-phase three-column or three-phase four-column or other multi-phase multi-column magnetic integrated inductor structure.

[0106] It should also be noted that the number of first skeletons 101-1-1 and second skeletons 101-1-2 is not limited and can be any number greater than or equal to 1, and the shapes can be the same or different. Similarly, the number of cores 101-2 is also not limited and can be any number greater than or equal to 1.

[0107] Specifically, after the iron core 101-2 is installed in place, the iron core center column 101-2-2 is placed in the skeleton center column 101-1-4, and the iron core yoke column 101-2-1 is placed in the skeleton yoke column 101-1-3; the skeleton center column 101-1-4 forms a circumferential covering on the iron core center column 101-2-2, and the inner cavity wall of the skeleton center column 101-1-4 and the circumferential outer wall of the iron core center column 101-2-2 are spaced 0.1mm-0.3mm; the skeleton yoke column 101-1-4 is placed in the skeleton yoke column 101-1-3; the skeleton yoke ... is placed in the skeleton yoke column 101-1-3; the skeleton yoke column 101-1-4 is placed in the skeleton yoke column 101-1-4; the skeleton yoke column 101-1-4 is placed in the skeleton yoke column 101-1-3; the skeleton yoke column 101-1-4 is placed in the skeleton yoke column 101-1-3; the skeleton yoke column 101-1-4 is placed in the skeleton yoke column 101-1-3; the skeleton yoke column 101-1-4 is placed in the skeleton yoke column 1 The insulating inner cavity of 1-1-3 matches the shape of the core yoke column 101-2-1. After the core yoke column 101-2-1 is installed, the skeleton yoke column 101-1-3 forms a covering state for the end of the core yoke column 101-2-1 close to the skeleton middle column 101-1-4 and the circumferential side of the core yoke column 101-2-1, and the inner cavity wall of the skeleton yoke column 101-1-3 and the circumferential outer wall of the core yoke column 101-2-1 are spaced 0.1mm-0.3mm apart. In this embodiment, taking the number of two skeleton center columns 101-1-4 as an example, the two skeleton center columns 101-1-4 and the skeleton yoke column 101-1-3 are set as an inner window 101-1a, as shown in Figure 13. The width t of the inner window 101-1a is determined according to the width of the winding 101-3, and the height H of the inner window 101-1a is determined according to the axial length of the winding 101-3. The wall thickness of the insulating skeleton 101-1 is designed and selected according to the mechanical strength and dielectric strength parameters of the non-metallic material, so as to withstand the total weight of the current product and the maximum voltage of the winding 101-3 to the iron core 101-2.

[0108] The structures of the first skeleton 101-1-1 and the second skeleton 101-1-2 are symmetrical, and the skeleton middle column 101-1-4 of the first skeleton 101-1-1 and the skeleton middle column 101-1-4 of the second skeleton 101-1-2 form a nested and plug-in structure. Taking the skeleton middle column 101-1-4 of the second skeleton 101-1-2 inserted into the skeleton middle column 101-1-4 of the first skeleton 101-1-1 as an example, the gap between the inner cavity wall of the skeleton middle column 101-1-4 of the first skeleton 101-1-1 and the outer wall of the skeleton middle column 101-1-4 of the second skeleton 101-1-2 is 0.1mm-0.3mm. After the first skeleton 101-1-1 and the second skeleton 101-1-2 are nested and plugged in, they form an integral insulating skeleton 101-1.

[0109] It should be noted that the structure of the insulating skeleton 101-1 disclosed above, including the first skeleton 101-1-1 and the second skeleton 101-1-2, is only a specific embodiment of the present application. In actual applications, the insulating skeleton 101-1 can also be set as an integrated skeleton structure. The present application facilitates the installation of the iron core 101-2 and the winding 101-3 by setting the first skeleton 101-1-1 and the second skeleton 101-1-2 in the insulating skeleton 101-1 to be plugged into each other.

[0110] In some embodiments, the iron core 101 - 2 is completely contained in the containing cavity, as shown in FIG8 , thereby reducing the exposed area of ​​the iron core 101 - 2 and further improving the protection of the iron core 101 - 2 .

[0111] It can be understood that the above-disclosed iron core 101 - 2 being completely accommodated in the accommodation cavity is only a specific embodiment of the present application. In actual application, a part of the iron core 101 - 2 can also be arranged to extend outside the accommodation cavity.

[0112] In some embodiments, the first frame 101-1-1 and the second frame 101-1-2 are respectively provided with locking members for locking the iron core 101-2. The first frame 101-1-1 and the second frame 101-1-2 respectively accommodate the corresponding iron core 101-2, and the provision of the locking members ensures that the iron core 101-2 is stably accommodated in the accommodation cavity.

[0113] Specifically, as shown in Figure 14, a portion of core 101-2 extends outside the cavity. Specifically, the end of core 101-2 facing away from center column 101-1-4 extends outside the cavity. The locking member includes a buckle 101-1-5, which is used to clamp onto the end face of core 101-2 extending outside the cavity, thereby increasing the clamping force of core 101-2 and enhancing the overall strength of inductor 100.

[0114] In order to further improve the stable clamping of the iron core 101-2, a specific embodiment of the present application discloses that there are multiple clips 101-1-5, which are spaced apart and arranged on the side walls of the skeleton yoke column 101-1-3.

[0115] It should be noted that the locking member disclosed above, including the buckle 101-1-5, is only a specific embodiment of the present application. In actual applications, the locking member can also be provided with a bolt and a block, that is, the buckle 101-1-5 is replaced by a bolt and a block, and the block is fixed to the bolt by a nut. A boss with a threaded hole is provided on the side wall of the skeleton yoke column 101-1-3. The bolt is threadedly connected to the threaded hole on the boss. By rotating the bolt, the block is driven to clamp or loosen the iron core 101-2.

[0116] In some embodiments, the inductor body 101 further includes a locking device, which is used to lock the first frame 101-1-1 and the second frame 101-1-2, thereby improving the connection stability between the first frame 101-1-1 and the second frame 101-1-2.

[0117] As shown in Figure 15, a specific embodiment of the present application discloses a locking device including a hook 101-6 and a slot 101-7, wherein, a hook 101-6 is provided on one of the first skeleton 101-1-1 and the second skeleton 101-1-2, and a slot 101-7 is provided on the other. When the first skeleton 101-1-1 and the second skeleton 101-1-2 are inserted into place, the hook 101-6 and the slot 101-7 are engaged to achieve self-locking of the first skeleton 101-1-1 and the second skeleton 101-1-2, thereby improving the connection stability of the first skeleton 101-1-1 and the second skeleton 101-1-2.

[0118] It should be noted that the locking device is not limited to the above structure, and may also be other structures. For example, the locking device includes a locking screw, etc.

[0119] In some embodiments, the first skeleton 101-1-1 and the second skeleton 101-1-2 are respectively clamped on the non-metallic connector 102-2 to facilitate the connection between the insulating skeleton 101-1 and the non-metallic connector 102-2, and eliminate the fasteners connecting the insulating skeleton 101-1 and the non-metallic connector 102-2, thereby reducing costs.

[0120] As shown in Figures 1-4 , the first frame 101-1-1 and the non-metallic connector 102-2 each have a first engaging groove 102-2a defined on one side, and a first engaging protrusion 101-1-1a that engages with the first engaging groove 102-2a on the other side. Specifically, the first engaging groove 102-2a and the first engaging protrusion 101-1-1a are used to achieve the engaging connection between the first frame 101-1-1 and the non-metallic connector 102-2.

[0121] The second frame 101-1-2 and the non-metallic connector 102-2 each have a second engaging groove 102-2b defined on one side, and a second engaging protrusion 101-1-2a engaged with the second engaging groove 102-2b on the other side. This allows the second frame 101-1-2 to engage with the non-metallic connector 102-2 by virtue of the second engaging groove 102-2b and the second engaging protrusion 101-1-2a.

[0122] It is understood that the number of first engaging protrusions 101-1-1a, first engaging grooves 102-2a, second engaging protrusions 101-1-2a, and second engaging grooves 102-2b is not limited and can be set arbitrarily. In this embodiment, the number of first engaging protrusions 101-1-1a and first engaging grooves 102-2a is equal and arranged in a one-to-one correspondence; the number of second engaging protrusions 101-1-2a and second engaging grooves 102-2b is equal and arranged in a one-to-one correspondence.

[0123] It should be noted that the first skeleton 101-1-1 and the second skeleton 101-1-2 are not limited to being connected to the non-metallic connector 102-2 in the above-mentioned manner. Locking buckles can also be set on the first skeleton 101-1-1 and / or the second skeleton 101-1-2 to achieve connection to the non-metallic connector 102-2 through the locking buckles.

[0124] To facilitate the connection between the first frame 101-1-1 and / or the second frame 101-1-2 and the non-metallic connector 102-2, a specific embodiment of the present application discloses a first snap-in slot 102-2a and / or the second snap-in slot 102-2b having a snap-in slot structure with one end open and the other end sealed. The first snap-in slot 102-2a cooperates with the first frame 101-1-1 to facilitate the first frame 101-1-1 sliding into the first snap-in slot 102-2a along the open end of the first snap-in slot 102-2a, and the sealed end of the first snap-in slot 102-2a limits the position of the first frame 101-1-1. Similarly, the cooperation between the second snap-in groove 102-2a and the second skeleton 101-1-1 facilitates the second skeleton 101-1-1 to slide into the second snap-in groove 102-2a along the open end of the second snap-in groove 102-2a, and the blocking setting at the other end of the second snap-in groove 102-2a realizes the limitation of the second skeleton 101-1-1.

[0125] It is understandable that the first snap-in groove 102-2a and the second snap-in groove 102-2b are not limited to snap-in groove structures with uniform cross-sections, but may also be snap-in groove structures with variable cross-sections. As long as the structures can achieve the snap-in position limiting of the first snap-in groove 102-2a on the first frame 101-1-1, and the snap-in position limiting of the second snap-in groove 102-2b on the second frame 101-1-2, they fall within the scope of protection of this application. In order to improve the snap-in firmness of the first frame 101-1-1, one embodiment of this application discloses that the cross-section of the first snap-in groove 102-2a gradually decreases from the open end to the blocked end. Similarly, in order to improve the snap-in firmness of the second frame 101-1-2, one embodiment of this application discloses that the cross-section of the second snap-in groove 102-2b gradually decreases from the open end to the blocked end.

[0126] In this embodiment, taking the first snap-in slot 102-2a and the second snap-in slot 102-2b as an example, both are snap-in slot structures and have the same shape, the first snap-in slot 102-2a and the second snap-in slot 102-2b have the same shape, so that the first skeleton 101-1-1 can also be plugged into the second snap-in slot 102-2b, and the second skeleton 101-1-2 can be plugged into the first snap-in slot 102-2a, realizing the interchangeability of the first snap-in slot 102-2a and the second snap-in slot 102-2b, which facilitates the installation of the first skeleton 101-1-1 and the second skeleton 101-1-2.

[0127] The first snap-fitting groove 102-2a and the second snap-fitting groove 102-2b are respectively located at the two ends of the insertion direction of the first skeleton 101-1-1 and the second skeleton 101-1-2 on the non-metallic connecting part 102-2, and the open end of the first snap-fitting groove 102-2a and the open end of the second snap-fitting groove 102-2b are arranged opposite to each other, so that the first skeleton 101-1-1 slides into the first snap-fitting groove 102-2a along the open end of the first snap-fitting groove 102-2a, and the second skeleton 101-1-2 slides into the second snap-fitting groove 102-2b along the open end of the second snap-fitting groove 102-2b.

[0128] When the cross-sections of the first clamping groove 102-2a and the second clamping groove 102-2b gradually decrease from the open end to the blocked end, it is convenient to clamp the first clamping protrusion 101-1-1a or the second clamping protrusion 101-1-2a.

[0129] To prevent the first engaging protrusion 101-1-1a from dislodging from the top of the first engaging groove 102-2a, the first engaging groove 102-2a may have a cross-section that gradually tapers from the bottom to the top, or a step may be formed to hold the first engaging protrusion 101-1-1a in place. Similarly, the second engaging groove 102-2b may have a cross-section that gradually tapers from the bottom to the top, or a step may be formed to hold the second engaging protrusion 101-1-2a in place.

[0130] The first engaging protrusion 101-1-1a is adapted to the shape of the first engaging groove 102-2a, and the second engaging protrusion 101-1-2a is adapted to the shape of the second engaging groove 102-2b.

[0131] In some embodiments, the inductor body 101 further includes a locking structure for locking the first frame 101-1-1 and the second frame 101-1-2 to the non-metallic connector 102-2, thereby further improving the connection stability between the first frame 101-1-1 and the second frame 101-1-2 and the flange structure 102.

[0132] The locking structure can be any structure that can improve the connection stability between the insulating frame and the flange structure. For example, the locking structure includes a locking fastener 101-4, and the first frame 101-1-1 and the second frame 101-1-2 are respectively fastened to the flange structure through the locking fastener 101-4.

[0133] It should be noted that the locking fastener 101 - 4 is a screw or a bolt.

[0134] A specific embodiment of the present application discloses at least one locking fastener 101-4 that passes through the accommodating cavity and limits the iron core 101-2. That is, the locking fastener 101-4 is a through-bolt. The through-bolt not only ensures the connection stability between the first frame 101-1-1 and the second frame 101-1-2 and the non-metallic connector 102-2, but also limits the position of the iron core 101-2, thereby improving the stability of the iron core 101-2 installed in the accommodating cavity. As shown in Figure 16, a locking fastener 101-4 passes through the accommodating cavity and limits the iron core 101-2. It can be understood that Figure 16 only shows a specific example of a locking fastener 101-4 passing through the accommodating cavity and limiting the iron core 101-2, but is not limited to using only one locking fastener 101-4. Two or more locking fasteners 101-4 can also be provided.

[0135] It should be noted that the present application is not limited to locking the insulating skeleton 101-1 by penetrating the accommodating cavity with a locking fastener 101-4 and limiting the iron core 101-2. At least one locking fastener 101-4 may also be provided separately or simultaneously to penetrate the accommodating cavity and the iron core 101-2 respectively. Specifically, at least one through-hole is provided on the skeleton yoke column 101-1-3 and the iron core 101-2, and the diameter of the through-hole is greater than the outer diameter of the thread of the through-bolt, and the difference between the two is greater than or equal to 0.2 mm. A threaded hole is provided on the non-metallic connector 102-2, and the outer diameter of the threaded hole is the same as that of the through-bolt. The insulating skeleton 101-1, the iron core 101-2 and the flange structure 102 are fastened together as a whole by the through-bolt, thereby improving the mechanical strength. It should be noted that the material of the through-bolt can be selected from high-strength metal materials such as brass, stainless steel, carbon steel, etc., or high-strength non-metallic materials such as nylon and fiberglass. The threaded holes can be made by self-tapping through holes, casting embedded nuts, wire thread inserts and other methods.

[0136] It is understandable that the locking structures disclosed in the above embodiments are only some specific implementation methods in this application. In actual applications, the locking structures can also be set to other structural forms, and the number of locking structures used to lock the insulating skeleton 101-1 to the flange structure 102 is not limited to 1. Two or more locking structures can be used. When the number of locking structures used is greater than or equal to 2, the types of locking structures can be the same or different. This application provides other types of locking structures. Specifically, the locking structure includes a tightening member 101-5, which is used to tie the insulating skeleton 101-1 to the flange structure 102.

[0137] As shown in FIG17 , along the direction of insertion perpendicular to the first skeleton 101-1-1 and the second skeleton 101-1-2, the first skeleton 101-1-1 and the second skeleton 101-1-2 are respectively constrained to the flange structure 102 by tightening members 101-5. More specifically, the first skeleton 101-1-1 can be configured to be restrained on the non-metallic connector 102-2 by corresponding tightening members 101-5, and the second skeleton 101-1-2 can be restrained on the non-metallic connector 102-2 by corresponding tightening members 101-5. It should be noted that the first skeleton 101-1-1 can also be configured to be restrained on the flange frame 102-1 by corresponding tightening members 101-5, and the second skeleton 101-1-2 can be restrained on the flange frame 102-1 by corresponding tightening members 101-5.

[0138] Of course, the first frame 101-1-1 and the second frame 101-1-2 can also be fastened separately or simultaneously using the same tightening member 101-5. In this case, along the insertion direction of the first frame 101-1-1 and the second frame 101-1-2, the tightening member 101-5 spans the first frame 101-1-1 and the second frame 101-1-2 to bind the first frame 101-1-1 and the second frame 101-1-2 to the non-metallic connector 102-2. As shown in Figures 18 to 20, an embodiment of fastening the first frame 101-1-1 and the second frame 101-1-2 using the same tightening member 101-5 is provided. Using this method, not only is the first frame 101-1-1 and the second frame 101-1-2 stably connected to the non-metallic connector 102-2, but the connection stability of the first frame 101-1-1 and the second frame 101-1-2 is also improved. It should be noted that the tightening member 101 - 5 in FIG. 17 and the tightening member 101 - 5 in FIG. 18 may also be used simultaneously to fix the insulating frame 101 - 1 , thereby improving the fixing stability.

[0139] When the locking structure includes a tightening member 101-5, an embodiment of the present application specifically discloses that the tightening member 101-5 includes an insulating tape 101-5a and a tightening metal tape 101-5b. As shown in FIG17 , the two ends of the tightening metal tape 101-5b are respectively connected to the flange structure 102, which is used to restrain the first frame 101-1-1 and / or the second frame 101-1-2. The non-metallic connecting member 102-2 is sleeved on the outside of the tightening metal tape 101-5b and contacts the first frame 101-1-1 and / or the second frame 101-1-2, isolating the tightening metal tape 101-5b from the first frame 101-1-1 and / or the second frame 101-1-2. The provision of the tightening metal tape 101-5b ensures the strength of the tightening member 101-5, and the provision of the insulating tape 101-5a achieves insulation between the tightening metal tape 101-5b and the insulating frame 101-1.

[0140] It is understandable that the number of tightening metal belts 101-5b can also be set to two, connected to the two ends of the insulating belt 101-5a respectively, the insulating belt 101-5a restrains the first skeleton 101-1-1 and / or the second skeleton 101-1-2, and the tightening metal belt 101-5b is connected to the non-metallic connector 102-2. The insulating belt 101-5a is in contact with the first skeleton 101-1-1 and the second skeleton 101-1-2, which further improves the insulation performance of the iron core 101-2 and the winding 101-3. It should be noted that when the number of tightening members 101-5 included in the locking structure is greater than or equal to 2, the structures of the tightening members 101-5 can be the same or different.

[0141] As shown in Figure 18, the first frame 101-1-1 and the second frame 101-1-2 are each connected to the non-metallic connector 102-2 via a tightening member 101-5. Taking the tightening member 101-5 on the first frame 101-1-1 side as an example, the tightening member 101-5 is provided on the frame yoke 101-1-3. The two tightening metal bands 101-5b each have at least one tightening through-hole. The diameter of the tightening through-hole is larger than the outer diameter of the tightening fastening bolt, with the difference between the two being greater than or equal to 0.2 mm. Fastening threaded holes are provided at corresponding positions on the non-metallic connector 102-2, and these fastening threaded holes are compatible with the tightening fastening bolts. By tightening the fastening bolts and tightening member 101-5, the circumference of the first frame 101-1-1 is tightened, thereby fastening the first frame 101-1-1, the core 101-2, and the non-metallic connector 102-2 into a single unit, improving mechanical strength. Similarly, the tightening member 101 - 5 on the second frame 101 - 1 - 2 side is similar to the tightening member 101 - 5 on the first frame 101 - 1 - 1 side.

[0142] It should be noted that the tightening member 101 - 5 can also be configured as a thin steel belt or a braided belt.

[0143] It should also be noted that the specific structure of the tightening member 101-5 disclosed above, including the insulating tape 101-5a and the tightening metal tape 101-5b, is only one type disclosed in this application. In actual applications, the tightening member 101-5 can also be set to other types of structures. For example, as shown in Figures 19 and 20, the tightening member 101-5 includes an end plate 101-5c and a tensioning member 101-5d. The number of end plates 101-5c is 2, and the two end plates 101-5c are respectively connected to the non-metallic connecting member 102-2 as shown in Figure 19; or, the two end plates 101-5c pass through the non-metallic member and are connected to the flange frame 102-1, as shown in Figures 20 and 21.

[0144] When the tightening member 101-5 includes an end plate 101-5c and a tensioning member 101-5d, along the insertion direction of the first frame 101-1-1 and the second frame 101-1-2, at least one end plate 101-5c is positioned at one end of the insulating frame 101-1, and at least one end plate 101-5c is positioned at the other end of the insulating frame 101-1. One end of the tensioning member 101-5d tensions the at least one end plate at one end of the insulating frame 101-1, and the other end tensions the at least one end plate at the other end of the insulating frame 101-1. Specifically, the tensioning member 101-5d is a tensioning bolt, etc.

[0145] It should be noted that the locking of the insulating frame 101-1 when the tightening member disclosed above includes the end plate 101-5c and the tensioning member 101-5d is only a specific embodiment of the present application. In actual applications, the end plate 101-5c and the tensioning member 101-5d can be set as other connection methods. For example, along the vertical insertion direction of the first frame 101-1-1 and the second frame 101-1-2, at least one end plate 101-5c is placed at one end of the first frame 101-1-1, and at least one end plate 101-5c is placed at the other end of the first frame 101-1-1. One end of the tensioning member 101-5d tensions at least one end plate 101-5c at one end of the first frame 101-1-1, and the other end tensions at least one end plate 101-5c at the other end of the first frame 101-1-1. Of course, it is also possible that at least one end plate 101-5c is placed at one end of the second skeleton 101-1-2 and at least one end plate 101-5c is placed at the other end of the second skeleton 101-1-2 along the insertion direction perpendicular to the first skeleton 101-1-1 and the second skeleton 101-1-2, and one end of the tensioning member 101-5d tensions at least one end plate 101-5c at one end of the second skeleton 101-1-2, and the other end tensions at least one end plate 101-5c at the other end of the second skeleton 101-1-2.

[0146] It is understood that the above-mentioned type of structure, when the tightening member includes the end plate 101-5c and the tensioning member 101-5d, can be used alone to lock a single insulating frame 101-1, or at least two types can be used. In other words, the insulating frame 101-1 is not limited to being locked by a single tightening member. Two or more tightening members 101-5 can also be provided to lock the same insulating frame 101-1. In this case, each tightening member 101-5 can be identical, or at least two different tightening members can be provided.

[0147] In order to improve the stable limiting of the first skeleton 101-1-1 and the second skeleton 101-1-2, a specific embodiment of the present application discloses that a limiting bending portion is provided on the end plate 101-5c for limiting contact with the top of the first skeleton 101-1-1 or the second skeleton 101-1-2. As shown in Figure 19, the end plate 101-5c is in a two-stage stepped shape, and the bottom end is fixed to the non-metallic connector 102-2 by fasteners such as bolts. The top end is tightened by tightening the end plates 101-5c on both sides by tightening the screws, applying a restraining force in the axial and height directions of the iron core 101-2, thereby ensuring the overall connection stability.

[0148] Of course, other methods can also be used to improve the stable positioning of the first skeleton 101-1-1 and the second skeleton 101-1-2. For example, a threaded hole is provided on the end plate 101-5c, and the fastener passes through the threaded hole and abuts against the first skeleton 101-1-1 or the second skeleton 101-1-2. Specifically, as shown in Figure 20, the interval between the end plate 101-5c and the iron core 101-2 is 0.2mm. Between the two end plates 101-5c, locking is performed by tightening the screw, and an insulating sleeve can be provided on the tightening screw to strengthen insulation. The iron core 101-2 is pressed by the fastener to apply an axial clamping force to the iron core 101-2, ensuring that the iron core 101-2 is stably limited within the first skeleton 101-1-1 and the second skeleton 101-1-2.

[0149] It should be noted that the width of the end plate 101-5c can be less than, equal to or greater than the width of the iron core 101-2; the end plate 101-5c can be a straight plate type, an L-shaped inward-facing angle steel type, an L-shaped outward-facing angle steel type, a U-shaped inward-facing channel steel type, a U-shaped outward-facing channel steel type or a combination of other shapes; the end plate 101-5c can be integrally connected to the non-metallic connector 102-2, bolt-fastened connection, slot connection, perforation connection, riveting, welding or other forms of connection, etc., and can also be integrally connected to the flange frame 102, etc.

[0150] It can be understood that the above-disclosed tightening screw located above the insulating frame 101-1 is only a specific embodiment of the present application. In actual applications, the tightening screw can also be arranged to be located below, on the left, on the right, or inside the insulating frame 101-1 (by opening a hole in the core yoke column 101-2-1 for locking), etc.

[0151] In some embodiments, a terminal block 101-3a is provided on the inductor body 101, and a wire outlet hole 102a is provided on the non-metallic connector 102-2 to allow the terminal block 101-3a to pass through, and the wire outlet hole 102a and the terminal block 101-3a are sealed with a sealant to ensure that air cannot enter the first cavity through the gap between the terminal block 101-3a and the wire outlet hole 102a.

[0152] Specifically, the number of outlet holes 102a is equal to the number of lead wires of the winding 101-3, and they are arranged in a one-to-one correspondence. The size of the outlet hole 102a is larger than the size of the outlet row, and the difference between the two is greater than 0.1mm. As shown in Figure 2, a specific embodiment of the present application discloses that the end of the non-metallic connector 102-2 facing the flange frame 102-1 is provided with an outlet cavity 102b arranged around the outlet hole 102a. Among them, the outlet cavity 102b is open at both ends, one end is connected to the outlet hole 102a, and the other end is arranged facing the first cavity, and the terminal block 101-3a can pass through the outlet cavity 102b and extend into the first cavity. Specifically, the number of outlet cavities 102b is equal to the number of outlet holes 102a, and they are arranged in a one-to-one correspondence. The provision of the outlet cavity 102b increases the creepage distance between the terminal block 101-3a and the flange frame 102-1.

[0153] In one embodiment of the present application, the single-side dimension of the outlet cavity 102b is approximately 2-5 times the width or length of the terminal block 101-3a, and the hole depth of the outlet cavity 102b is approximately 10 mm. It is understood that the dimensions of the outlet cavity 102b disclosed above are only one specific embodiment of the present application, and in actual application, other dimensions can be set as needed to meet the actual application requirements.

[0154] In some embodiments, the material of the iron core 101-2 can be any soft magnetic material, such as pure iron, iron silicon, iron silicon aluminum, iron nickel, iron nickel molybdenum, iron cobalt vanadium, ferrite, silicon steel, amorphous and nanocrystalline materials, etc., and can also be an air-core coil. It should be noted that the material of the iron core 101-2 is not limited to the above materials; any material that can be used as a magnetic core is within the scope of protection of this application.

[0155] As shown in FIG11 , each core column 101 - 2 - 2 of the core 101 - 2 includes N (N is a positive integer greater than or equal to 1) magnetic columns, and N + 1 air gaps with intervals of millimeters are set between these N parts. Then, the magnetic columns are equivalent to magnetic columns made of magnetic materials with lower magnetic permeability. Alternatively, no air gap is set, and the magnetic columns are magnetic columns with the current magnetic permeability.

[0156] The conductor structure of the winding 101-3 can be round conductor, flat conductor, foil strip, ladder wire or Litz wire; the material can be copper or aluminum; the winding 101-3 can be wound in a multi-layer flat winding or a multi-layer / single-layer vertical winding.

[0157] The connection mode of the input and output wires of the winding 101-3 can be a flexible connection, a hard connection, or a combination of a flexible and a hard connection. For example, the input and output wires of the winding 101-3 can all be hard connections, or flexible connections, or the input wires can be hard connections and the output wires can be flexible connections, or the input wires can be flexible connections and the output wires can be hard connections.

[0158] The incoming and outgoing wires of the winding 101-3 are led out through the outlet hole 102a, and the outlet hole 102a is sealed and reinforced by pouring sealant. The sealant can be epoxy resin, silicone, plastic or other easily sealed insulating materials. At the same time, other sealing methods can also be used at this position, for example, adding a sealing gland, a sealing gasket, an integral casting sealing method, etc.

[0159] In some embodiments, to meet the requirements of protection level and heat dissipation, the inductor 100 adopts the following types of insulation treatment processes, but is not limited to the following: (1) dipping process and surface spraying of three-proof covering paint. The insulation level of the insulating dipping paint and three-proof paint is generally H level, and can also be A level, B level, F level or C level; (2) overall dipping process. The dipping process can be silicone, polyurethane or epoxy glue. Through overall dipping, a protective layer is formed on the surface of the inductor 100 to protect the inductor 100 as a whole; (4) electrostatic spraying (5) Winding 101-3 is wrapped with insulating paper and / or insulating tape 101-5a and an insulating protective layer 103 is formed by a varnishing process; (6) Winding 101-3 is individually encapsulated or cast to form insulation protection; (7) PVD vacuum coating insulation treatment process; (8) Surface glue brushing insulation process, etc., as well as other process methods. The inductor 100 is provided with insulation to achieve overall protection.

[0160] This application eliminates the traditional inductor metal heat sink and potting compound in the power circuit of inverter 1000, effectively reducing the cost of inverter 1000, while increasing the heat dissipation capacity of the inductor, reducing the conduction of inductor heat into the interior of inverter 1000, lowering the ambient temperature inside the inverter 1000 box, eliminating the internal stress of the inductor, improving the temperature resistance level of the inductor, and effectively improving the overall reliability of inverter 1000. At the same time, the inductor 100 is simple and easy to maintain, reducing the operation and maintenance detection costs of inverter 1000.

[0161] In some embodiments, as shown in FIG. 22 , the inductor 100 further includes a protective layer 103 covering the inductor body 101 to the flange structure 102 .

[0162] Specifically, the protective layer 103 can be integrally cast through a casting process to form the protective layer 103 , ie, a protective shell structure, which can effectively protect and insulate the inductor body 101 .

[0163] It should be noted that the above-disclosed method of forming the protective layer 103 is only a specific implementation of the present application. In practical applications, other methods may also be used. For example, an injection molding process may be used to form a protective shell structure.

[0164] In one embodiment of the present application, the inductor 100 can be accommodated in the second cavity, and the first cavity has higher protection than the second cavity. On the one hand, the second cavity can protect the inductor 100, and on the other hand, ventilation can be introduced into the second cavity to improve the heat dissipation efficiency of the inductor 100.

[0165] Power converter 1000 employs an inductor. The power converter 1000 comprises a first cavity and a second cavity, each separated by a partition. Specifically, the first cavity is a clean room, and the second cavity is a ventilation cavity. A connecting hole is provided in the cavity wall separating the first and second cavities. Inductor 100 is located in the second cavity to achieve rapid heat dissipation.

[0166] It can be understood that the above-disclosed inductor 100 housed in the second cavity is only a specific embodiment of the present application. In actual applications, the inductor 100 can also be directly housed in the first cavity. Of course, part of the inductor can also be housed in the second cavity, and the remaining part can be housed in at least one other cavity. The number and shape of the cavities can be adaptively selected according to the structure of the inductor 100.

[0167] As shown in FIG. 23 , a second aspect of the present application provides a power converter 1000 , comprising an inductor 100 as in any one of the above embodiments.

[0168] It should be noted that the power converter 1000 can be any type of converter, and is not limited to a specific converter or converters. For example, the power converter 1000 can be a DC-AC converter, a DC-DC converter, or an AC-DC converter.

[0169] As shown in FIG23 , taking the power converter 1000 as an inverter in a DC-AC converter as an example, the inverter further includes a DC / DC circuit 200 and a DC / AC circuit 300 , and the rear ends of the DC / DC circuit 200 and the rear ends of the DC / AC circuit 300 are respectively connected to the inductor 100 .

[0170] It can be understood that the power converter 1000 disclosed above as an inverter is only a specific implementation of the present application. In actual applications, the power converter 1000 can also be set as other types of converters.

[0171] Since the power converter 1000 provided in the present application includes the inductor 100 in any one of the above embodiments, the beneficial effects of the above inductor 100 are all included in the power converter 1000 disclosed in the present application.

[0172] A third aspect of the present application provides a power conversion system, including the power converter 1000 as in the above embodiment or the inductor 100 as in any one of the above embodiments.

[0173] Since the power conversion system provided in the present application includes the power converter 1000 in the above embodiment or the inductor 100 in any one of the above embodiments, the beneficial effects of the above power converter 1000 or the above inductor 100 are all included in the power conversion system disclosed in the present application.

[0174] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0175] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the widest scope consistent with the principles and inventive features disclosed herein.

[0176] Throughout this specification, references to terms such as "one embodiment," "example," or "specific example" indicate that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0177] The preferred embodiments of the present application disclosed above are intended only to help illustrate the present application. The preferred embodiments do not describe all details in detail, nor do they limit the present application to specific embodiments. Obviously, many modifications and variations can be made based on the contents of this specification. This specification selects and describes these embodiments in detail to better explain the principles and practical applications of the present application, so that those skilled in the art can better understand and utilize the present application. The present application is limited only by the claims and their full scope and equivalents.

Claims

1. An inductor (100), characterized in that: include: Inductor body (101); A flange structure (102), the flange structure (102) comprising a flange frame (102-1) and a non-metallic connector (102-2), the flange frame (102-1) being used to connect to a first cavity, the non-metallic connector (102-2) being fixed on the flange frame (102-1), and the inductor body (101) being fixed on an end of the non-metallic connector (102-2) facing away from the flange frame (102-1).

2. The inductor (100) according to claim 1, characterized in that The inductor body (101) comprises: an insulating frame (101-1), wherein the insulating frame (101-1) is fixed on the non-metallic connecting piece (102-2); An iron core (101-2) and a winding (101-3), wherein the iron core (101-2) and the winding (101-3) are respectively arranged on the insulating frame (101-1), and the iron core (101-2) and the winding (101-3) are insulated.

3. The inductor (100) according to claim 2, characterized in that The insulating frame (101-1) includes a first frame (101-1-1) and a second frame (101-1-2); The first frame (101-1-1) and the second frame (101-1-2) each have an accommodation cavity for accommodating the iron core (101-2); The first skeleton (101-1-1) and the second skeleton (101-1-2) are respectively fixed on the non-metallic connecting member (102-2) and arranged to be plugged in, and the winding (101-3) is sleeved outside the plugging portion formed by the plugging of the first skeleton (101-1-1) and the second skeleton (101-1-2).

4. The inductor (100) according to claim 3, characterized in that The first frame (101-1-1) and the second frame (101-1-2) are respectively clamped on the non-metallic connecting piece (102-2).

5. The inductor (100) according to claim 4, characterized in that One of the first frame (101-1-1) and the non-metallic connector (102-2) is provided with a first clamping groove (102-2a), and the other is provided with a first clamping protrusion (101-1-1a) clamped with the first clamping groove (102-2a); And / or, a second engaging groove (102-2b) is provided on one of the second frame (101-1-2) and the non-metallic connecting member (102-2), and a second engaging protrusion (101-1-2a) engaging with the second engaging groove (102-2b) is provided on the other.

6. The inductor (100) according to claim 5, characterized in that The first clamping slot (102-2a) and / or the second clamping slot (102-2b) is a clamping slot structure with one end being open and the other end being closed.

7. The inductor (100) according to claim 3, characterized in that The inductor body (101) further includes a locking structure; The locking structure is used to lock the first frame (101-1-1) and the second frame (101-1-2) to the non-metallic connecting member (102-2).

8. The inductor (100) according to claim 7, characterized in that The locking structure comprises a locking fastener (101-4), and the first frame (101-1-1) and the second frame (101-1-2) are respectively fastened to the flange structure (102) via the locking fastener (101-4); And / or, the locking structure includes a tightening member (101-5); along the insertion direction perpendicular to the first frame (101-1-1) and the second frame (101-1-2), the first frame (101-1-1) and the second frame (101-1-2) are respectively bound to the flange joint by the tightening member (101-5). structure (102); and / or, along the insertion direction of the first skeleton (101-1-1) and the second skeleton (101-1-2), the tightening member (101-5) spans the first skeleton (101-1-1) and the second skeleton (101-1-2) to constrain the first skeleton (101-1-1) and the second skeleton (101-1-2) to the flange structure (102).

9. The inductor (100) according to claim 8, characterized in that At least one locking fastener (101-4) passes through the accommodating cavity and limits the iron core (101-2); And / or, at least one of the locking fasteners (101-4) passes through the accommodating cavity and the iron core (101-2) respectively.

10. The inductor (100) according to claim 8, characterized in that The tightening member (101-5) comprises an insulating belt (101-5a) and a tightening metal belt (101-5b), the two ends of the tightening metal belt (101-5b) being respectively connected to the flange structure (102) for restraining the first frame (101-1-1) and / or the second frame (101-1-2), the non-metallic connecting member (102-2) being sleeved outside the tightening metal belt (101-5b) and in contact with the first frame (101-1-1) and / or the second frame (101-1-2), thereby isolating the tightening metal belt (101-5b) from the first frame (101-1-1) and / or the second frame (101-1-2); And / or, the tightening member (101-5) includes an end plate (101-5c) and a tensioning member (101-5d), the end plate (101-5c) is connected to the non-metallic connecting member (102-2) or penetrates the non-metallic member and is connected to the flange frame (102-1); along the plug-in direction of the first skeleton (101-1-1) and the second skeleton (101-1-2), at least one end plate (101-5c) is placed at one end of the insulating skeleton (101-1), at least one end plate (101-5c) is placed at the other end of the insulating skeleton (101-1), one end of the tensioning member (101-5d) tensions at least one end plate (101-5c) at one end of the insulating skeleton (101-1), and the other end tensions the other end of the insulating skeleton (101-1). At least one of the end plates (101-5c); and / or, along the direction of insertion perpendicular to the first skeleton (101-1-1) and the second skeleton (101-1-2), at least one of the end plates (101-5c) is placed at one end of the first skeleton (101-1-1), and at least one of the end plates (101-5c) is placed at the other end of the first skeleton (101-1-1), one end of the tensioning member (101-5d) tensions at least one of the end plates (101-5c) at one end of the first skeleton (101-1-1), and the other end tensions at least one of the end plates at the other end of the first skeleton (101-1-1). (101-5c); and / or, along the insertion direction perpendicular to the first skeleton (101-1-1) and the second skeleton (101-1-2), at least one of the end plates (101-5c) is placed at one end of the second skeleton (101-1-2), and at least one of the end plates (101-5c) is placed at the other end of the second skeleton (101-1-2), and one end of the tensioning member (101-5d) tensions at least one of the end plates (101-5c) at one end of the second skeleton (101-1-2), and the other end tensions at least one of the end plates (101-5c) at the other end of the second skeleton (101-1-2).

11. The inductor (100) according to claim 10, characterized in that The end plate (101-5c) is provided with a position-limiting bending portion that abuts against the top of the first frame (101-1-1) or the second frame (101-1-2) in a limited position; and / or, A threaded hole is provided on the end plate (101-5c), and a fastener passes through the threaded hole and abuts against the first frame (101-1-1) or the second frame (101-1-2).

12. The inductor (100) according to any one of claims 3 to 11, characterized in that: The first frame (101-1-1) and the second frame (101-1-2) both include a frame yoke column (101-1-3) and a frame center column (101-1-4); The skeleton center column (101-1-4) is fixed to the skeleton yoke column (101-1-3) and communicates with the inner cavity of the skeleton center column (101-1-4). The core yoke column (101-2-1) of the iron core (101-2) The core (101-2-2) of the iron core (101-2) is accommodated in the skeleton yoke column (101-1-3); The skeleton center column (101-1-4) of the first skeleton (101-1-1) and the skeleton center column (101-1-4) of the second skeleton (101-1-2) are inserted into each other to form the inserting portion.

13. The inductor (100) according to claim 12, characterized in that The iron core (101-2) is completely accommodated in the accommodation cavity.

14. The inductor (100) according to claim 12, characterized in that The first frame (101-1-1) and the second frame (101-1-2) are respectively provided with locking parts for locking the iron core (101-2).

15. The inductor (100) according to claim 14, characterized in that A portion of the iron core (101-2) extends outside the accommodating cavity; The locking member comprises a buckle (101-1-5), and the buckle (101-1-5) is used to clamp the end surface of the iron core (101-2) extending outside the accommodating cavity.

16. The inductor (100) according to claim 3, characterized in that The inductor body (101) further comprises a locking device for locking the first frame (101-1-1) and the second frame (101-1-2).

17. The inductor (100) according to claim 16, characterized in that The locking device comprises a hook (101-6) and a slot (101-7); Of the first frame (101-1-1) and the second frame (101-1-2), one is provided with the hook (101-6), and the other is provided with a slot (101-7); When the first skeleton (101-1-1) and the second skeleton (101-1-2) are inserted into place, The hook (101-6) is engaged with the slot (101-7).

18. The inductor (100) according to any one of claims 1 to 12, characterized in that: The non-metallic connecting piece (102-2) is provided with a wire outlet hole (102a) for allowing the wiring block (101-3a) of the inductor body (101) to pass through, and the wire outlet hole (102a) and the wiring block (101-3a) are sealed by a sealant.

19. The inductor (100) according to claim 18, characterized in that An outlet cavity (102b) arranged around the outlet hole (102a) is provided at one end of the non-metallic connector (102-2) facing the flange frame (102-1); The two ends of the outlet cavity (102b) are open, one end is connected to the outlet hole (102a), and the other end is used to face the first cavity, and the wiring block (101-3a) can pass through the outlet cavity (102b) and extend into the first cavity.

20. The inductor (100) according to any one of claims 1 to 12, characterized in that: The flange frame (102-1) is provided with a connecting piece (102-3) for connecting with the first cavity; A sealing groove is provided at one end of the flange frame (102-1) facing away from the non-metallic connector (102-2), a sealing ring (102-4) is installed in the sealing groove, and the sealing ring (102-4) is arranged around the connector (102-3) and is in sealing contact with the cavity wall of the first cavity.

21. The inductor (100) according to claim 20, characterized in that The connecting piece (102-3) comprises: a connecting fastener threadedly connected to the flange frame (102-1), and / or a bolt fastener connected to the flange frame (102-1), and / or a plug connector connected to the flange frame (102-1).

22. The inductor (100) according to any one of claims 1 to 12, characterized in that: It also includes a protective layer (103) covering the inductor body (101) to the flange structure (102).

23. The inductor (100) according to any one of claims 1 to 12, characterized in that: The inductor (100) can be accommodated in the second cavity, and the protection of the first cavity is higher than that of the second cavity.

24. A power converter (1000), characterized in that: The invention comprises an inductor (100) according to any one of claims 1 to 23.

25. A power conversion system, characterized in that: The method comprises the power converter (1000) according to claim 24 or the inductor (100) according to any one of claims 1 to 23.

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