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

An inductor, a power converter, and a power conversion system

[0001] This application claims priority to Chinese Patent Application No. 202410374680.7, filed on March 29, 2024, entitled "An Inductor, Power Converter and Power Conversion System", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of power converter technology, and in particular to an inductor, a power converter, and a power conversion system. Background Technology

[0003] Inductors are crucial components responsible for energy transfer, storage, and filtering. Current inductors employ a shell-type casting structure, where the inductor body is encapsulated within a metal heat sink using potting compound for insulation, and then sealed and fixed to the cavity by the heat sink. The addition of the metal heat sink and potting compound increases the inductor's weight and cost.

[0004] Summary of the Invention

[0005] In view of this, the first objective of this application is to provide an inductor that reduces the weight and cost of the inductor.

[0006] The second objective of this application is to provide a power converter.

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

[0008] To achieve the first objective mentioned above, this application provides the following solution:

[0009] An inductor, comprising:

[0010] Inductor body;

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

[0012] In one specific implementation, the inductor body includes:

[0013] An insulating frame, which is fixed to the non-metallic connector;

[0014] The iron core and the winding are respectively disposed on the insulating frame, and the iron core and the winding are insulated from each other.

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

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

[0017] The first frame and the second frame are respectively fixed on the non-metallic connector and are interlocked. The winding is fitted outside the interlocking part formed by the first frame and the second frame.

[0018] In another specific embodiment, the first skeleton and the second skeleton are respectively snapped onto the non-metallic connector.

[0019] In another specific implementation, in the first frame and the non-metallic connector, one has a first snap-fit ​​groove, and the other has a first snap-fit ​​protrusion that snaps into the first snap-fit ​​groove.

[0020] And / or, in the second skeleton and the non-metallic connector, one has a second snap-fit ​​groove, and the other has a second snap-fit ​​protrusion that snaps into the second snap-fit ​​groove.

[0021] In another specific implementation, the first and / or second snap-fit ​​slots are snap-fit ​​slot structures with one end open and the other end sealed.

[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 connector.

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

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

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

[0027] And / or, at least one of the locking fasteners penetrates both the receiving cavity and the iron core.

[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 for binding the first skeleton and / or the second skeleton. The non-metallic connector is sleeved on the tightening metal tape and contacts the first skeleton and / or the second skeleton, isolating and insulating the tightening metal tape from the first skeleton and / or the second skeleton.

[0029] And / or, the tightening member includes an end plate and a tensioning member, the end plate being connected to or penetrating the non-metallic connector and connected to the flange frame; along the interlocking direction of the first frame and the second frame, at least one end plate is placed at one end of the insulating frame, 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 interlocking direction perpendicular to the first frame and the second frame, at least one end plate is placed... At least one end plate is placed at one end of the first frame and at the other end of the first frame. One end of the tensioning member tensions at least one end plate at one end of the first frame and at least one end plate at the other end of the first frame. And / or, along the insertion direction perpendicular to the first frame and the second frame, at least one end plate is placed at one end of the second frame and at least one end plate is placed at the other end of the second frame. One end of the tensioning member tensions at least one end plate at one end of the second frame and at least one end plate at the other end of the second frame.

[0030] In another specific implementation, the end plate is provided with a limiting bend that abuts against the top of the first frame or the second frame;

[0031] And / or,

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

[0033] In another specific implementation, both the first skeleton and the second skeleton include a skeleton yoke column and a skeleton central column;

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

[0035] The central column of the first frame is inserted into the central column of the second frame to form the insertion part.

[0036] In another specific implementation, the iron core is completely housed within the receiving cavity.

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

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

[0039] The locking element includes a latch for locking the end face of the iron core extending outside the receiving 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] In the first frame and the second frame, one is provided with the hook and the other is provided with the slot;

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

[0044] In another specific embodiment, the non-metallic connector has an outlet hole that allows the terminal block of the inductor body to pass through, and the outlet hole is sealed to the terminal block by sealant.

[0045] In another specific implementation, the non-metallic connector has a cable outlet cavity surrounding the cable outlet hole at one end facing the flange frame;

[0046] The cable outlet cavity is open at both ends, with one end communicating with the cable outlet hole and the other end facing the first cavity. The terminal block can extend through the cable outlet cavity into the first cavity.

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

[0048] The flange frame has a sealing groove at the end opposite to the non-metallic connector. A sealing ring is installed in the sealing groove. The sealing ring surrounds the connector and seals against the cavity wall of the first cavity.

[0049] In another specific embodiment, the connector includes: a connecting fastener threaded 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 onto the flange structure.

[0051] In another specific embodiment, the inductor can be housed within a second cavity, and the first cavity has higher protective properties than the second cavity.

[0052] The various embodiments of this application can be combined arbitrarily as needed, and the resulting embodiments are also within the scope of this application and are part of the specific implementation methods of this application.

[0053] The inductor provided in this application achieves an insulated connection with the flange structure by fixing the inductor body to a non-metallic connector of the flange structure, and connects to the first cavity through the flange frame of the flange structure. The non-metallic connector ensures the insulation performance of the inductor body, allowing direct heat dissipation and improving heat dissipation efficiency, thus avoiding impact on the maximum operating temperature of the power inductor. By fixing the non-metallic connector to the flange frame, this application provides sufficient strength for the flange structure to secure the inductor body, eliminating the need for a metal heat sink and potting compound, thereby reducing the cost and weight of the inductor.

[0054] To achieve the second objective mentioned above, this application provides the following solution:

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

[0056] Since the power converter provided in this application includes the inductor mentioned in any of the above, the beneficial effects of the aforementioned inductor are all included in the power converter disclosed in this application.

[0057] To achieve the third objective mentioned above, this application provides the following solution:

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

[0059] Since the power conversion system provided in this application includes the power converter described above or the inductor in any of the above-mentioned categories, the beneficial effects of the power converter or the inductor described above are all included in the power conversion system disclosed in this application. Attached Figure Description

[0060] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0061] Figure 1 is a three-dimensional structural diagram of an inductor in one angular direction provided in the first embodiment of this application;

[0062] Figure 2 is a three-dimensional structural diagram of the inductor provided in the first embodiment of this application in another angular direction;

[0063] Figure 3 is a three-dimensional structural diagram of the flange structure provided in this application;

[0064] Figure 4 is an exploded structural diagram of the flange structure provided in this application;

[0065] Figure 5 is a three-dimensional structural diagram of the inductor provided in the second embodiment of this application;

[0066] Figure 6 is a three-dimensional structural diagram of an inductor in another angular direction provided in the first embodiment of this application;

[0067] Figure 7 is a three-dimensional structural diagram of the inductor provided in the third embodiment of this application;

[0068] Figure 8 is a three-dimensional structural diagram of the inductor body provided in this application;

[0069] Figure 9 is a three-dimensional structural schematic diagram of the insulating skeleton provided in the first embodiment of this application;

[0070] Figure 10 is an exploded structural diagram of the insulating skeleton provided in the first embodiment of this application;

[0071] Figure 11 is a three-dimensional structural diagram of the iron core provided in this application when it is to be assembled;

[0072] Figure 12 is a three-dimensional structural schematic diagram of the insulating skeleton provided in the fourth embodiment of this application;

[0073] Figure 13 is a schematic diagram of the structure of the first skeleton provided in the first embodiment of this application;

[0074] Figure 14 is a three-dimensional structural diagram of the iron core being installed into the insulating frame according to the fifth embodiment of this application;

[0075] Figure 15 is a three-dimensional structural schematic diagram of the insulating skeleton provided in the sixth embodiment of this application;

[0076] Figure 16 is a three-dimensional structural diagram of the inductor provided in the seventh embodiment of this application;

[0077] Figure 17 is a three-dimensional structural diagram of the inductor provided in the eighth embodiment of this application;

[0078] Figure 18 is a three-dimensional structural diagram of the inductor provided in the ninth embodiment of this application;

[0079] Figure 19 is a three-dimensional structural diagram of the inductor provided in the tenth embodiment of this application;

[0080] Figure 20 is a three-dimensional structural schematic diagram of the inductor provided in the eleventh embodiment of this application;

[0081] Figure 21 is a three-dimensional structural diagram of the connection between the end plate and the flange frame provided in the eleventh embodiment of this application;

[0082] Figure 22 is a three-dimensional structural schematic diagram of the inductor provided in the twelfth embodiment of this application;

[0083] Figure 23 is a schematic diagram of the inverter provided in this application.

[0084] In Figures 1-23: Inverter 1000, Inductor 100, Inductor Body 101, Insulating Frame 101-1, Inner Window 101-1a, First Frame 101-1-1, First Snap-on Protrusion 101-1-1a, Second Frame 101-1-2, Second Snap-on Protrusion 101-1-2a, Frame Yoke 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 Piece 101-5, Insulating Tape 101-5a, Tightening Metal Tape 101-5b, End Plate 101-5c, Tensioner 101-5d, Hook 101-6, Slot 101-7, Flange Structure 102, Flange Frame 102-1, Reinforcing Rib 102-1a, Mounting Hole Seat 102-1b, Non-metallic Connector 102-2, First Snap-fit ​​Slot 102-2a, Second Snap-fit ​​Slot 102-2b, Iron Core Yoke 101-2-1, Iron Core Central Column 101-2-2, Outlet Hole 102a, Outlet Cavity 102b, Connector 102-3, Sealing Ring 102-4, Protective Layer 103, DC / DC Circuit 200, DC / AC Circuit 300. Detailed Implementation

[0085] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to Figures 1-23. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0086] Referring to Figures 1-23, the first aspect of this 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 a 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 from the outside; alternatively, the inductor 100 can be entirely placed inside the first cavity and sealed to the first cavity from the inside. This article will use the example of the inductor 100 being entirely placed outside the first cavity for illustration. Understandably, the installation method of the inductor 100 being placed inside the first cavity is similar to that of it being placed outside the first cavity.

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

[0089] It should be noted that the flange frame 102-1 is made of a non-magnetic material with a certain strength and rigidity. It can be a metallic material, such as aluminum or aluminum alloy; or a non-metallic material with sufficient strength and rigidity, such as fiberglass. In this embodiment, the flange frame 102-1 is made of a metallic material as an example. As shown in Figure 4, the flange frame 102-1 has a hollow frame structure. Its shape and size depend on the inductor body 101, and its thickness meets the design requirements for product strength.

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

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

[0092] A sealing groove is provided at the end of the flange frame 102-1 opposite to the non-metallic connector 102-2. A sealing ring 102-4 is installed in the sealing groove, surrounding the connector 102-3 and sealingly abutting against the cavity wall of the first cavity. The flange frame 102-1 achieves a sealed connection with the first cavity through the sealing ring 102-4, improving the protection of the first cavity. Furthermore, the sealing ring 102-4 surrounds the connector 102-3, and the pressure generated by the connector 102-3 connecting to the first cavity compresses the sealing ring 102-4, ensuring a firm seal against the cavity wall of the first cavity. This avoids the problem of gaps at the connection between the connector 102-3 and the first cavity, which would affect the sealing effect if the connector 102-3 were located outside the sealing ring 102-4. Specifically, the sealing ring 102-4 can be formed in the sealing groove by adhesive sealing strips or by applying sealant.

[0093] To improve the strength of the flange frame 102-1 at the connection point with the connector 102-3, one specific embodiment of this application discloses a mounting hole seat 102-1b at the connection point of the flange frame 102-1 and the connector 102-3, as shown in Figure 4. 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 towards the end closer to the non-metallic connector 102-2. This increases the mechanical strength at the connection point with the connector 102-3. Furthermore, a positioning groove that matches the mounting hole seat 102-1b can be provided at the corresponding position of the non-metallic connector 102-2, increasing the adhesive strength between the non-metallic connector 102-2 and the flange frame 102-1. When the connector 102-3 includes a 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 connecting the connector 102-3. The flange frame 102-1 is also provided with at least one reinforcing rib 102-1a to increase the deformation resistance of the flange frame 102-1, thereby improving the adhesion between it 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 and the circumferential side of the non-metallic connector 102-2. This structure provides insulation between the energized high-voltage winding 101-3 on the inductor body 101 and the non-metallic frame. When the inductor 100 is located outside the first cavity, it can also reduce the inductor heat conducted into the first cavity. Specifically, the material of the non-metallic frame can be epoxy, 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] To improve the connection stability between the non-metallic connector 102-2 and the flange frame 102-1 and achieve a seal between them, one specific embodiment of this application discloses that the flange frame 102-1 and the non-metallic connector 102-2 are connected using an integral casting process. It is understood that using an integral casting process to connect the flange frame 102-1 and the non-metallic connector 102-2 is only one specific embodiment of this application. In practical applications, other connection methods can also be used between the flange frame 102-1 and the non-metallic connector 102-2. For example, the flange frame 102-1 and the metal connector can be detachably fastened using fasteners and sealed with a sealant. By fixing the non-metallic connector 102-2 to the flange frame 102-1, this application ensures that the flange structure 102 has sufficient insulation strength to fix the inductor body 101, eliminating the need for a metal heat sink housing and potting compound, thus reducing the cost and weight of the inductor 100.

[0096] The inductor body 101 is fixed to one end of the non-metallic connector 102-2 away from the flange frame 102-1. The non-metallic connector 102-2 serves two purposes: firstly, it provides insulation isolation from the first cavity, ensuring the insulation performance of the inductor body 101 and allowing it to dissipate heat directly, thus improving heat dissipation efficiency and preventing it from affecting the maximum operating temperature of the power inductor; secondly, it provides a sealed isolation between the inductor body 101 and the first cavity, eliminating the need for additional sealing gaskets / adhesives and further reducing the cost of the inductor 100.

[0097] In this embodiment, the terminal block 101-3a on the inductor body 101 is sealed through the non-metallic connector 102-2 and extends into the first cavity to achieve connection with the electrical components 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 non-metallic insulating material and mainly serves as a mechanical structural fixing component and main 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 set to any shape and structure that allows for the installation of 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 insulation of the iron core 101-2 from being broken down by the winding 101-3.

[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 snapped onto the non-metallic connector 102-2, or it can be detachably connected to the non-metallic connector 102-2 by fasteners or the like, or it can be riveted to the non-metallic connector 102-2 by anchors or the like. Similarly, the second frame 101-1-2 can be snapped onto the non-metallic connector 102-2, or it can be detachably connected to the non-metallic connector 102-2 by fasteners or the like, or it can be riveted to the non-metallic connector 102-2 by anchors or the like.

[0102] The first frame 101-1-1 and the second frame 101-1-2 are interlocked, and the winding 101-3 is fitted outside the interlocking part formed by the first frame 101-1-1 and the second frame 101-1-2. The inclusion cavity and the interlocking part are designed to achieve insulation between the iron core 101-2 and the winding 101-3, preventing insulation breakdown failure of the winding 101-3 to the iron core 101-2.

[0103] As shown in Figure 10, in one specific embodiment of this application, both the first frame 101-1-1 and the second frame 101-1-2 include a frame yoke 101-1-3 and a frame central column 101-1-4. The frame central column 101-1-4 is fixed to the frame yoke 101-1-3 and communicates with the inner cavity of the frame central column 101-1-4. It should be noted that both the frame central column 101-1-4 and the frame yoke 101-1-3 are open-ended and hollow columnar structures. The core yoke 101-2-1 of the core 101-2 is housed within the frame yoke 101-1-3, and the core central column 101-2-2 of the core 101-2 is housed within the frame central column 101-1-4.

[0104] The central column 101-1-4 of the first frame 101-1-1 is inserted into the central column 101-1-4 of the second frame 101-1-2 to form an interlocking part.

[0105] It should be noted that the number of central pillars 101-1-4 in either the first frame 101-1-1 or the second frame 101-1-2 is unlimited. As shown in Figure 10, there are two central pillars 101-1-4, which are alternately arranged on the yoke pillars 101-1-3. It should also be noted that the number of central pillars 101-1-4 is not limited to two; it can also be three or more. The shapes of the central pillars 101-1-4 can be the same or different. For example, as shown in Figure 12, both the first frame 101-1-1 and the second frame 101-1-2 have three central pillars 101-1-4. Within the same first frame 101-1-1 or second frame 101-1-2, two central pillars 101-1-4 have the same shape, both being cylindrical; one central pillar 101-1-4 has a different shape, being a square cylinder. At this point, the square cylindrical skeleton column 101-1-4 can be used as a guide device instead of placing the iron core yoke 101-2-1 inside it, which also improves the bending resistance of the skeleton yoke 101-1-3. Of course, it is also possible to place the iron core yoke 101-2-1 inside at least one skeleton column 101-1-4 to form different types of inductor core structures, such as two-phase three-column or three-phase four-column multi-phase multi-column magnetic integrated inductor structures.

[0106] It should also be noted that the number of the first frame 101-1-1 and the second frame 101-1-2 is not limited; it can be any number greater than or equal to 1, and their shapes can be the same or different. Similarly, the number of iron cores 101-2 is also not limited; it 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 post 101-2-2 is placed inside the skeleton center post 101-1-4, and the iron core yoke post 101-2-1 is placed inside the skeleton yoke post 101-1-3; the skeleton center post 101-1-4 circumferentially covers the iron core center post 101-2-2, and the inner cavity wall of the skeleton center post 101-1-4 is spaced 0.1mm-0.3mm from the outer circumferential wall of the iron core center post 101-2-2; the skeleton yoke post 101-2-1... The insulating inner cavity of 1-1-3 matches the shape of the iron core yoke 101-2-1. After the iron core yoke 101-2-1 is installed, the skeleton yoke 101-1-3 covers the end of the iron core yoke 101-2-1 near the skeleton central column 101-1-4 and the circumferential side of the iron core yoke 101-2-1. The inner cavity wall of the skeleton yoke 101-1-3 is spaced 0.1mm-0.3mm from the circumferential outer wall of the iron core yoke 101-2-1. In this embodiment, taking two skeleton columns 101-1-4 as an example, the two skeleton columns 101-1-4 and the skeleton yoke column 101-1-3 enclose 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 be able to withstand the total weight of the current product and withstand the highest voltage of the winding 101-3 to the iron core 101-2.

[0108] The first skeleton 101-1-1 and the second skeleton 101-1-2 are symmetrical in structure, and the skeleton central column 101-1-4 of the first skeleton 101-1-1 and the skeleton central column 101-1-4 of the second skeleton 101-1-2 form a nested interlocking structure. Taking the skeleton central column 101-1-4 of the second skeleton 101-1-2 inserted into the skeleton central column 101-1-4 of the first skeleton 101-1-1 as an example, the gap between the inner cavity wall of the skeleton central column 101-1-4 of the first skeleton 101-1-1 and the outer wall of the skeleton central 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 interlocked, they form an integral insulating skeleton 101-1.

[0109] It should be noted that the above-disclosed insulating frame 101-1, including the first frame 101-1-1 and the second frame 101-1-2, is only one specific embodiment of this application. In practical applications, the insulating frame 101-1 can also be configured as an integrally formed frame structure. This application facilitates the installation of the iron core 101-2 and the winding 101-3 by setting the first frame 101-1-1 and the second frame 101-1-2 in the insulating frame 101-1 to be interlocked.

[0110] In some embodiments, the iron core 101-2 is completely housed within the receiving cavity, as shown in FIG8, which reduces the exposed area of ​​the iron core 101-2 and further improves the protection of the iron core 101-2.

[0111] It is understood that the above-disclosed iron core 101-2 being completely contained within the receiving cavity is only one specific embodiment of this application. In practical applications, a portion of the iron core 101-2 may also be arranged to extend outside the receiving cavity.

[0112] In some embodiments, locking members for locking the iron core 101-2 are respectively provided on 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 respectively accommodate the corresponding iron core 101-2, and the locking members enable the iron core 101-2 to be stably accommodated in the accommodating cavity.

[0113] Specifically, as shown in Figure 14, a portion of the iron core 101-2 extends outside the receiving cavity. Specifically, the end of the iron core 101-2 opposite to the central post 101-1-4 of the frame extends outside the receiving cavity. The locking element includes a latch 101-1-5, which is used to lock the end face of the iron core 101-2 extending outside the receiving cavity, thereby increasing the clamping constraint force on the iron core 101-2 and increasing the overall strength of the inductor 100.

[0114] To further improve the stable clamping of the iron core 101-2, one specific embodiment of this application discloses that there are multiple buckles 101-1-5, which are arranged at intervals around the side wall of the skeleton yoke 101-1-3.

[0115] It should be noted that the locking component disclosed above, including the buckle 101-1-5, is only one specific embodiment of this application. In practical applications, the locking component can also include bolts and locking blocks, that is, bolts and locking blocks can be used to replace buckle 101-1-5. The locking block is fixed to the bolt by a nut. The side wall of the skeleton yoke 101-1-3 is provided with a boss with a threaded hole. The bolt is threadedly connected to the threaded hole on the boss. By rotating the bolt, the locking block can be driven to lock or release the iron core 101-2.

[0116] In some embodiments, the inductor body 101 further includes a locking device for locking 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 this application discloses a locking device including a hook 101-6 and a slot 101-7. The first frame 101-1-1 and the second frame 101-1-2 are provided with a hook 101-6 on one and a slot 101-7 on the other. When the first frame 101-1-1 and the second frame 101-1-2 are inserted into each other, the hook 101-6 engages with the slot 101-7 to achieve self-locking between 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.

[0118] It should be noted that the locking device is not limited to the structure described above, but can also be other structures, such as locking screws.

[0119] In some embodiments, the first skeleton 101-1-1 and the second skeleton 101-1-2 are respectively snapped onto 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 need for fasteners to connect the insulating skeleton 101-1 and the non-metallic connector 102-2, thereby reducing costs.

[0120] Referring to Figures 1-4, in the first frame 101-1-1 and the non-metallic connector 102-2, one has a first snap-fit ​​groove 102-2a, and the other has a first snap-fit ​​protrusion 101-1-1a that snaps into the first snap-fit ​​groove 102-2a. That is, the snap-fit ​​between the first frame 101-1-1 and the non-metallic connector 102-2 is achieved through the arrangement of the first snap-fit ​​groove 102-2a and the first snap-fit ​​protrusion 101-1-1a.

[0121] In the second frame 101-1-2 and the non-metallic connector 102-2, one has a second snap-fit ​​groove 102-2b, and the other has a second snap-fit ​​protrusion 101-1-2a that snaps into the second snap-fit ​​groove 102-2b. That is, the snap-fit ​​between the second frame 101-1-2 and the non-metallic connector 102-2 is achieved by the arrangement of the second snap-fit ​​groove 102-2b and the second snap-fit ​​protrusion 101-1-2a.

[0122] Understandably, the number of the first latching protrusion 101-1-1a, the first latching groove 102-2a, the second latching protrusion 101-1-2a, and the second latching groove 102-2b is unlimited and can be arbitrarily set. In this embodiment, the number of the first latching protrusion 101-1-1a and the first latching groove 102-2a are equal and are set in a one-to-one correspondence; the number of the second latching protrusion 101-1-2a and the second latching groove 102-2b are equal and are set in a one-to-one correspondence.

[0123] It should be noted that the first frame 101-1-1 and the second frame 101-1-2 are not limited to being snapped into the non-metallic connector 102-2 in the manner described above. Locking buckles can also be provided on the first frame 101-1-1 and / or the second frame 101-1-2 to achieve snapping into the non-metallic connector 102-2.

[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, one specific embodiment of this application discloses a snap-fit ​​groove structure in which both the first snap-fit ​​groove 102-2a and / or the second snap-fit ​​groove 102-2b are open at one end and sealed at the other end. The way the first snap-fit ​​groove 102-2a engages with the first frame 101-1-1 allows the first frame 101-1-1 to slide into the first snap-fit ​​groove 102-2a along the open end of the first snap-fit ​​groove 102-2a, and the sealing of the other end of the first snap-fit ​​groove 102-2a limits the position of the first frame 101-1-1. Similarly, the way the second locking groove 102-2a and the second frame 101-1-1 are matched makes it easy for the second frame 101-1-1 to slide into the second locking groove 102-2a along the open end of the second locking groove 102-2a, and the sealing setting at the other end of the second locking groove 102-2a realizes the limitation of the second frame 101-1-1.

[0125] Understandably, the first snap-fit ​​groove 102-2a and the second snap-fit ​​groove 102-2b are not limited to snap-fit ​​groove structures with a constant cross-section; they can also be snap-fit ​​groove structures with a variable cross-section. As long as they satisfy the requirement of snap-fit ​​limiting the first snap-fit ​​groove 102-2a to the first frame 101-1-1 and the second snap-fit ​​groove 102-2b to the second frame 101-1-2, the structure falls within the protection scope of this application. To improve the snap-fit ​​strength to the first frame 101-1-1, one embodiment of this application discloses that the cross-section of the first snap-fit ​​groove 102-2a gradually decreases along the direction from the open end to the closed end. Similarly, to improve the snap-fit ​​strength to the second frame 101-1-2, one embodiment of this application discloses that the cross-section of the second snap-fit ​​groove 102-2b gradually decreases along the direction from the open end to the closed end.

[0126] In this embodiment, taking the first snap-fit ​​slot 102-2a and the second snap-fit ​​slot 102-2b as having the same shape and being snap-fit ​​slot structures as an example, the first snap-fit ​​slot 102-2a and the second snap-fit ​​slot 102-2b have the same shape, so that the first frame 101-1-1 can also be inserted into the second snap-fit ​​slot 102-2b, and the second frame 101-1-2 can be inserted into the first snap-fit ​​slot 102-2a, realizing the interchangeability of the first snap-fit ​​slot 102-2a and the second snap-fit ​​slot 102-2b, which facilitates the installation of the first frame 101-1-1 and the second frame 101-1-2.

[0127] The first locking groove 102-2a and the second locking groove 102-2b are respectively located at the two ends of the first skeleton 101-1-1 and the second skeleton 101-1-2 on the non-metallic connector 102-2 in the interlocking direction. The open end of the first locking groove 102-2a and the open end of the second locking groove 102-2b are arranged opposite to each other, so that the first skeleton 101-1-1 can slide along the open end of the first locking groove 102-2a into the first locking groove 102-2a, and the second skeleton 101-1-2 can slide along the open end of the second locking groove 102-2b into the second locking groove 102-2b.

[0128] When both the first locking groove 102-2a and the second locking groove 102-2b have a gradually decreasing cross-section along the direction from the open end to the sealed end, it is convenient to lock the first locking protrusion 101-1-1a or the second locking protrusion 101-1-2a.

[0129] To prevent the first snap-fit ​​protrusion 101-1-1a from dislodging from the top of the first snap-fit ​​groove 102-2a, the first snap-fit ​​groove 102-2a can be configured such that at least a portion of its cross-section gradually decreases along the direction from the bottom to the top of the groove, or a limiting step is formed to limit the first snap-fit ​​protrusion 101-1-1a. Similarly, the second snap-fit ​​groove 102-2b can also be configured such that at least a portion of its cross-section gradually decreases along the direction from the bottom to the top of the groove, or a limiting step is formed to limit the second snap-fit ​​protrusion 101-1-2a.

[0130] The first snap-fit ​​protrusion 101-1-1a is adapted to the shape of the first snap-fit ​​groove 102-2a, and the second snap-fit ​​protrusion 101-1-2a is adapted to the shape of the second snap-fit ​​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 fastener 101-4 is a screw or bolt, etc.

[0134] One specific embodiment of this application discloses at least one locking fastener 101-4 penetrating the receiving cavity and limiting the iron core 101-2. Specifically, the locking fastener 101-4 is a through bolt. The through bolt, while ensuring the connection stability between the first frame 101-1-1 and the second frame 101-1-2 and the non-metallic connector 102-2, also limits the iron core 101-2, improving the stability of the iron core 101-2 installed in the receiving cavity. As shown in Figure 16, one locking fastener 101-4 penetrates the receiving cavity and limits the iron core 101-2. It is understood that Figure 16 only shows a specific example of one locking fastener 101-4 penetrating the receiving cavity and limiting the iron core 101-2, but it is not limited to using only one locking fastener 101-4; two or more locking fasteners 101-4 can also be used.

[0135] It should be noted that this application is not limited to locking the insulating skeleton 101-1 by using a locking fastener 101-4 to penetrate the receiving cavity and limit the iron core 101-2. Alternatively, at least one locking fastener 101-4 can be used, either alone or simultaneously, to penetrate both the receiving cavity and the iron core 101-2. Specifically, the skeleton yoke 101-1-3 and the iron core 101-2 each have at least one through hole, and the diameter of the through hole is larger than the outer diameter of the threaded bolt, with the difference being greater than or equal to 0.2 mm. The non-metallic connector 102-2 has a threaded hole with the same outer diameter as the through bolt. The through bolt secures the insulating skeleton 101-1, the iron core 101-2, and the flange structure 102 into a single unit, improving mechanical strength. It should be noted that the through bolt can be made of high-strength metal materials such as brass, stainless steel, or carbon steel, or high-strength non-metallic materials such as nylon or fiberglass. For threaded holes, you can choose open-hole self-tapping screws, cast-in-place nuts, wire thread inserts, or other methods.

[0136] It is understood that the locking structures disclosed in the above embodiments are only some specific implementations of this application. In practical applications, the locking structure 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 one. Two or more locking structures can be used. When the number of locking structures used is greater than or equal to two, the type of locking structure 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 bind the insulating skeleton 101-1 to the flange structure 102.

[0137] As shown in Figure 17, 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 structure 102 by tightening members 101-5. More specifically, the first frame 101-1-1 can be positioned on the non-metallic connector 102-2 by the corresponding tightening member 101-5, and the second frame 101-1-2 can also be positioned on the non-metallic connector 102-2 by the corresponding tightening member 101-5. It should be noted that the first frame 101-1-1 can also be positioned on the flange frame 102-1 by the corresponding tightening member 101-5, and the second frame 101-1-2 can also be positioned on the flange frame 102-1 by the corresponding tightening member 101-5.

[0138] Of course, the first skeleton 101-1-1 and the second skeleton 101-1-2 can also be fastened together by the same tightening member 101-5, either individually or simultaneously. In this case, along the interlocking direction of the first skeleton 101-1-1 and the second skeleton 101-1-2, the tightening member 101-5 spans across the first skeleton 101-1-1 and the second skeleton 101-1-2 to bind the first skeleton 101-1-1 and the second skeleton 101-1-2 to the non-metallic connector 102-2. As shown in Figures 18-20, an embodiment in which the first skeleton 101-1-1 and the second skeleton 101-1-2 are fastened together by the same tightening member 101-5 is given. Using this method, not only is the first skeleton 101-1-1 and the second skeleton 101-1-2 stably connected to the non-metallic connector 102-2, but the connection stability of the first skeleton 101-1-1 and the second skeleton 101-1-2 is also improved. It should be noted that the tightening member 101-5 in Figure 17 and the tightening member 101-5 in Figure 18 can also be used to fix the insulating frame 101-1, thereby improving the fixing stability.

[0139] When the locking structure includes a tightening member 101-5, one embodiment of this application specifically discloses that the tightening member 101-5 includes an insulating strip 101-5a and a tightening metal strip 101-5b, as shown in FIG17. The two ends of the tightening metal strip 101-5b are respectively connected to the flange structure 102 for binding the first skeleton 101-1-1 and / or the second skeleton 101-1-2. A non-metallic connector 102-2 is sleeved on the outside of the tightening metal strip 101-5b and contacts the first skeleton 101-1-1 and / or the second skeleton 101-1-2, isolating the insulating tightening metal strip 101-5b from the first skeleton 101-1-1 and / or the second skeleton 101-1-2. The tightening metal strip 101-5b ensures the strength of the tightening member 101-5, and the insulating strip 101-5a achieves insulation between the tightening metal strip 101-5b and the insulating skeleton 101-1.

[0140] Understandably, the number of tightening metal strips 101-5b can also be set to two, respectively connected to both ends of the insulating strip 101-5a. The insulating strip 101-5a binds the first frame 101-1-1 and / or the second frame 101-1-2, and the tightening metal strip 101-5b is connected to the non-metallic connector 102-2. Through the contact between the insulating strip 101-5a and the first frame 101-1-1 and the second frame 101-1-2, the insulation performance between the core 101-2 and the winding 101-3 is further improved. It should be noted that when the number of tightening members 101-5 included in the locking structure is greater than or equal to two, 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 side of the first frame 101-1-1 as an example, the frame yoke 101-1-3 is provided with the tightening member 101-5, and each of the two tightening metal strips 101-5b is provided with at least one tightening through hole, and the diameter of the tightening through hole is larger than the outer diameter of the thread of the tightening bolt, with the difference being greater than or equal to 0.2 mm. A tightening threaded hole is opened at the corresponding position of the non-metallic connector 102-2, and the tightening threaded hole is adapted to the tightening bolt. By tightening the first frame 101-1-1 circumferentially with the tightening bolt and the tightening member 101-5, the first frame 101-1-1, the iron core 101-2, and the non-metallic connector 102-2 are fastened into a whole, 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 component 101-5 can also be made entirely of thin steel strip or braided strip.

[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 practical 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. There are two end plates 101-5c, and the two end plates 101-5c are respectively connected to the non-metallic connector 102-2 as shown in Figure 19; or, the two end plates 101-5c penetrate the non-metallic part and are connected to the flange frame 102-1, as shown in Figures 20 and 21.

[0144] When the tightening member 101-5 includes end plates 101-5c and tensioning members 101-5d, along the interlocking 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 insulating frame 101-1, and at least one end plate 101-5c is placed at the other end of the insulating frame 101-1. One end of the tensioning member 101-5d tensions at least one end plate at one end of the insulating frame 101-1, and the other end tensions 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 by the above-disclosed tightening member including end plate 101-5c and tensioning member 101-5d is only one specific embodiment of this application. In practical applications, the end plate 101-5c and tensioning member 101-5d can be set to other connection methods. For example, along the interlocking direction perpendicular to 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, at least one end plate 101-5c is placed at the other end of the first frame 101-1-1, one end of 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. Alternatively, along the interlocking direction perpendicular to 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 second frame 101-1-2, and at least one end plate 101-5c is placed at the other end of the second frame 101-1-2. One end of the tensioning member 101-5d tensions at least one end plate 101-5c at one end of the second frame 101-1-2, and the other end tensions at least one end plate 101-5c at the other end of the second frame 101-1-2.

[0146] Understandably, the aforementioned structure, including end plate 101-5c and tensioning member 101-5d, can be used alone for locking one insulating frame 101-1, or at least two types can be used. That is, it is not limited to locking the insulating frame 101-1 with one tensioning member; two or more tensioning members 101-5 can be used to lock the same insulating frame 101-1. In this case, the tensioning members 101-5 can be identical, or at least two can be different.

[0147] To improve the stability and limiting of the first frame 101-1-1 and the second frame 101-1-2, a specific embodiment of this application discloses that the end plate 101-5c is provided with a limiting bending part that abuts against the top of the first frame 101-1-1 or the second frame 101-1-2, as shown in FIG19. The end plate 101-5c is in the form of two stepped sections. The bottom end is fixed to the non-metallic connector 102-2 by fasteners such as bolts, and the top end is tightened by tension screws to tighten the end plates 101-5c on both sides, thereby applying constraint force in the axial and height directions of the iron core 101-2 and ensuring the overall connection stability.

[0148] Of course, other methods can also be used to improve the stability and limiting of the first frame 101-1-1 and the second frame 101-1-2. For example, the end plate 101-5c has a threaded hole, through which a fastener passes and abuts against the first frame 101-1-1 or the second frame 101-1-2. Specifically, as shown in Figure 20, the end plate 101-5c and the iron core 101-2 are spaced 0.2mm apart. The two end plates 101-5c are locked together by a tensioning screw, which can be fitted with an insulating sleeve to enhance insulation. The iron core 101-2 is pressed down by the fastener to apply an axial clamping force, ensuring that the iron core 101-2 is stably limited within the first frame 101-1-1 and the second frame 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, an L-shaped inward-facing angle steel, an L-shaped outward-facing angle steel, a U-shaped inward-facing channel steel, a U-shaped outward-facing channel steel or other combinations of shapes; the end plate 101-5c can be integrally connected with the non-metallic connector 102-2, bolted, slotted, perforated, riveted, welded or other forms of connection, or integrally connected with the flange frame 102.

[0150] Understandably, the above-disclosed tensioning screw located above the insulating frame 101-1 is only one specific embodiment of this application. In practical applications, the tensioning screw can also be located below, to the left, to the right of the insulating frame 101-1, or inside the insulating frame 101-1 (with a hole made in the iron core yoke 101-2-1 for locking), etc.

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

[0152] Specifically, the number of outlet holes 102a is equal to the number of leads of winding 101-3, and they are arranged in a one-to-one correspondence. The size of outlet hole 102a is larger than the size of outlet busbar, and the difference between the two is greater than 0.1mm. As shown in Figure 2, a specific embodiment of this application discloses that a non-metallic connector 102-2 has an outlet cavity 102b surrounding the outlet hole 102a at one end facing the flange frame 102-1. The outlet cavity 102b is open at both ends, with one end communicating with the outlet hole 102a and the other end facing the first cavity. The terminal block 101-3a can extend through the outlet cavity 102b 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 arrangement 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 this application, the single-side dimension of the cable outlet cavity 102b is approximately 2-5 times the width or length of the terminal block 101-3a, and the hole depth of the cable outlet cavity 102b is approximately 10mm. It is understood that the dimensions of the cable outlet cavity 102b disclosed above are only one specific embodiment of this application; in practical applications, other dimensions that meet usage requirements can also be used.

[0154] In some embodiments, the material of the 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., or it can be a hollow coil. It should be noted that the material of the core 101-2 is not limited to the above-mentioned materials; any material that can be used as a magnetic core is within the scope of protection of this application.

[0155] As shown in Figure 11, each core column 101-2-2 of the iron core 101-2 includes N (N is a positive integer greater than or equal to 1) magnetic columns. N+1 air gaps with a spacing on the order of millimeters are set between these N parts. Then the magnetic column is equivalent to a magnetic column made of a magnetic material with lower permeability. Alternatively, no air gaps can be set, and it can be a magnetic column with the current permeability.

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

[0157] The incoming and outgoing wires of winding 101-3 can be connected by a flexible connection, a rigid connection, or a combination of both. For example, the incoming and outgoing wires of winding 101-3 can all be connected by a rigid connection, or all can be connected by a flexible connection, or the incoming wires can be connected by a rigid connection and the outgoing wires by a flexible connection, or the incoming wires can be connected by a flexible connection and the outgoing wires by a rigid connection, etc.

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

[0159] In some embodiments, to meet the protection level and heat dissipation requirements, the inductor 100 adopts the following, but not limited to, insulation treatment processes: (1) impregnation process and surface spraying of three-proof coating, the insulation level of the insulating impregnation varnish and the three-proof coating is generally H class, but can also be A class, B class, F class or C class; (2) overall impregnation process, the impregnation process can be silicone, polyurethane or epoxy glue, etc., through overall impregnation, a protective layer is formed on the surface of the inductor 100 to provide overall protection for the inductor 100; (4) electrostatic spraying The process involves electrostatic spraying to apply an insulating layer to the exposed surface of winding 101-3, forming an insulating protective layer 103; (5) wrapping the outer surface of winding 101-3 with insulating paper and / or insulating tape 101-5a, and forming an insulating protective layer 103 through an impregnation process; (6) individually encapsulating or casting winding 101-3 to form an insulating protective layer; (7) PVD vacuum coating insulation treatment process; (8) surface brushing adhesive insulation process, and other process methods. The inductor 100 achieves overall protection through insulation settings.

[0160] This application eliminates the traditional metal heat sink and potting compound for the inductor in the medium power circuit of the inverter 1000, effectively reducing the cost of the inverter 1000. At the same time, it increases the heat dissipation capacity of the inductor, reduces the conduction of heat from the inductor to the inside of the inverter 1000, lowers the ambient temperature inside the inverter 1000 enclosure, eliminates the internal stress of the inductor, improves the inductor's temperature resistance rating, and effectively improves the overall reliability of the inverter 1000. In addition, the inductor 100 is simple, easy to maintain, and reduces the operation and maintenance testing costs of the inverter 1000.

[0161] In some embodiments, as shown in FIG22, 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 using a casting process to form the protective layer 103, i.e., the 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 one specific embodiment of this application. In practical applications, other methods can also be used, such as injection molding to form the protective shell structure.

[0164] In one embodiment of this application, the inductor 100 can be housed within a second cavity, and the first cavity has higher protective properties than the second cavity. On one hand, the second cavity can protect the inductor 100; on the other hand, ventilation can be introduced into the second cavity to improve the heat dissipation efficiency of the inductor 100.

[0165] An inductor is used in a power converter 1000, which has a first cavity and a second cavity separated by partitions. Specifically, the first cavity is a clean chamber, and the second cavity is a ventilation chamber. Through holes are provided on the walls of the partitions of the first and second cavities. The inductor 100 is located in the second cavity to achieve rapid heat dissipation.

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

[0167] As shown in FIG23, a second aspect of this application provides a power converter 1000, including an inductor 100 as described in any of the embodiments above.

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

[0169] As shown in Figure 23, taking the power converter 1000 as an inverter in a DC-AC converter as an example, the inverter also includes a DC / DC circuit 200 and a DC / AC circuit 300. The back end of the DC / DC circuit 200 and the back end of the DC / AC circuit 300 are respectively connected to the inductor 100.

[0170] It is understood that the power converter 1000 disclosed above as an inverter is only one specific embodiment of this application. In practical applications, the power converter 1000 can also be set as other types of converters.

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

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

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

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

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

[0176] In the description of this specification, the references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions 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 one or more embodiments or examples.

[0177] The preferred embodiments disclosed above are merely illustrative of this application. These preferred embodiments do not exhaustively describe all details, nor do they limit the application to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. The selection and detailed description of these embodiments in this specification are intended to better explain the principles and practical applications of this application, thereby enabling those skilled in the art to better understand and utilize this application. This 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) includes a flange frame (102-1) and a non-metallic connector (102-2). The flange frame (102-1) is used to connect to a first cavity. The non-metallic connector (102-2) is fixed on the flange frame (102-1). The inductor body (101) is fixed to one end of the non-metallic connector (102-2) away from the flange frame (102-1).

2. The inductor (100) according to claim 1, characterized in that, The inductor body (101) includes: An insulating frame (101-1) is fixed to the non-metallic connector (102-2); The iron core (101-2) and the winding (101-3) are respectively disposed on the insulating frame (101-1), and the iron core (101-2) and the winding (101-3) are insulated from each other.

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 a receiving cavity for accommodating the iron core (101-2); The first frame (101-1-1) and the second frame (101-1-2) are respectively fixed on the non-metallic connector (102-2) and are interlocked. The winding (101-3) is fitted outside the interlocking part formed by the first frame (101-1-1) and the second frame (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 snapped onto the non-metallic connector (102-2).

5. The inductor (100) according to claim 4, characterized in that, In the first frame (101-1-1) and the non-metallic connector (102-2), one has a first snap-fit ​​groove (102-2a) and the other has a first snap-fit ​​protrusion (101-1-1a) that snaps into the first snap-fit ​​groove (102-2a); And / or, in the second skeleton (101-1-2) and the non-metallic connector (102-2), one has a second snap-fit ​​groove (102-2b), and the other has a second snap-fit ​​protrusion (101-1-2a) that snaps into the second snap-fit ​​groove (102-2b).

6. The inductor (100) according to claim 5, characterized in that, The first snap-fit ​​groove (102-2a) and / or the second snap-fit ​​groove (102-2b) are snap-fit ​​groove structures with one end open and the other end sealed.

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

8. The inductor (100) according to claim 7, characterized in that, The locking structure includes a locking fastener (101-4), and the first skeleton (101-1-1) and the second skeleton (101-1-2) are respectively fastened to the flange structure (102) through the locking fastener (101-4); And / or, the locking structure includes a tightening member (101-5); along the interlocking direction 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 bound to the flange by the tightening member (101-5). On the structure (102); and / or, along the interlocking 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 bind 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 of the locking fasteners (101-4) penetrates the receiving cavity and limits the iron core (101-2); And / or, at least one of the locking fasteners (101-4) penetrates the receiving cavity and the iron core (101-2) respectively.

10. The inductor (100) according to claim 8, characterized in that, The tightening member (101-5) includes an insulating tape (101-5a) and a tightening metal tape (101-5b). The two ends of the tightening metal tape (101-5b) are respectively connected to the flange structure (102) for binding the first skeleton (101-1-1) and / or the second skeleton (101-1-2). The non-metallic connector (102-2) is sleeved on the tightening metal tape (101-5b) and contacts the first skeleton (101-1-1) and / or the second skeleton (101-1-2), isolating and insulating the tightening metal tape (101-5b) from the first skeleton (101-1-1) and / or the second skeleton (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) being connected to the non-metallic connector (102-2) or penetrating the non-metallic connector and being connected to the flange frame (102-1); along the interlocking 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 interlocking direction perpendicular to the first frame (101-1-1) and the second frame (101-1-2), at least one of the end plates (101-5c) is placed at one end of the first frame (101-1-1), at least one of the end plates (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 of the end plates (101-5c) at one end of the first frame (101-1-1), and the other end tensions at least one of the end plates at the other end of the first frame (101-1-1). (101-5c); and / or, along the interlocking direction perpendicular to the first frame (101-1-1) and the second frame (101-1-2), at least one of the end plates (101-5c) is placed at one end of the second frame (101-1-2), at least one of the end plates (101-5c) is placed at the other end of the second frame (101-1-2), one end of the tensioning member (101-5d) tensions at least one of the end plates (101-5c) at one end of the second frame (101-1-2), and the other end tensions at least one of the end plates (101-5c) at the other end of the second frame (101-1-2).

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

12. The inductor (100) according to any one of claims 3-11, characterized in 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); The central column (101-1-4) of the skeleton is fixed to the yoke column (101-1-3) of the skeleton and communicates with the inner cavity of the central column (101-1-4). The core yoke column (101-2-1) of the iron core (101-2) is also connected to the core yoke column (101-2-1). The iron core (101-2-2) of the iron core (101-2) is housed within the frame yoke column (101-1-3), and the iron core column (101-2-2) of the iron core (101-2) is housed within the frame column (101-1-4). The central column (101-1-4) of the first frame (101-1-1) is inserted into the central column (101-1-4) of the second frame (101-1-2) to form the inserted part.

13. The inductor (100) according to claim 12, characterized in that, The iron core (101-2) is completely contained within the receiving 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 members to lock 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 receiving cavity; The locking element includes a latch (101-1-5) for locking the end face of the iron core (101-2) extending outside the receiving cavity.

16. The inductor (100) according to claim 3, characterized in that, The inductor body (101) also includes 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 includes a hook (101-6) and a slot (101-7); In 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 the slot (101-7); When the first frame (101-1-1) and the second frame (101-1-2) are properly inserted into place, The hook (101-6) engages with the slot (101-7).

18. The inductor (100) according to any one of claims 1-12, characterized in that, The non-metallic connector (102-2) has an outlet hole (102a) that allows the terminal block (101-3a) of the inductor body (101) to pass through, and the outlet hole (102a) and the terminal block (101-3a) are sealed with sealant.

19. The inductor (100) according to claim 18, characterized in that, The non-metallic connector (102-2) has a cable outlet cavity (102b) surrounding the cable outlet hole (102a) at one end facing the flange frame (102-1); The cable outlet cavity (102b) is open at both ends, with one end communicating with the cable outlet hole (102a) and the other end facing the first cavity. The terminal block (101-3a) can extend through the cable outlet cavity (102b) into the first cavity.

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

21. The inductor (100) according to claim 20, characterized in that, The connector (102-3) includes: a connecting fastener threaded 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 1-12, 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 1-12, characterized in that, The inductor (100) can be housed in the second cavity, and the first cavity has higher protection than the second cavity.

24. A power converter (1000), characterized in that, Including the inductor (100) as described in any one of claims 1-23.

25. A power conversion system, characterized in that, Includes the power converter (1000) as described in claim 24 or the inductor (100) as described in any one of claims 1-23.

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