Inductor module

Abstract

An inductor module according to an embodiment of the present invention comprises: a housing forming an inner space; and at least one inductor disposed inside the housing, wherein the inductor includes a core and a winding wound around the core, the winding includes a plurality of layers wound around the core, and the directions in which first and second layers of the plurality of layers are wound around the core are opposite to each other.

Description

Inductor module

[0001] The present invention relates to an inductor module.

[0002] Solar power generation is becoming widely adopted as an eco-friendly energy source, replacing conventional chemical and nuclear power generation. Solar power generation can be either standalone, with a battery connected to a converter, or grid-connected. Standalone systems typically consist of solar cells, storage batteries, and power conversion equipment, while grid-connected systems are connected to commercial power sources, enabling the exchange of power with load grid lines.

[0003] The power generated by solar panels is difficult to use directly in homes or buildings, so it must be converted into usable power through a power conversion device such as an inverter. Inverters use inductors to boost voltage when performing power conversion. When using a wound inductor, parasitic capacitance increases as the number of winding layers increases during winding. In addition, when molding with a liquid containing metal components for heat dissipation, the permittivity of the metal components in the molding liquid combines with the coil, which increases parasitic capacitance.

[0004] The technical problem to be solved by the present invention is to provide an inductor module capable of reducing parasitic capacitors.

[0005] In order to solve the above technical problem, an inductor module according to one embodiment of the present invention includes a housing forming an internal space; and one or more inductors disposed inside the housing, wherein the inductor includes a core and a winding wound around the core, the winding includes a plurality of layers wound around the core, and the first layer and the second layer of the plurality of layers are wound in opposite directions around the core.

[0006] Additionally, the winding may include a first layer wound in both directions along the circumference of the core from a first point of the core toward a second point opposite to the first point; and a second layer wound on the first layer from the second point toward the first point along the circumference of the core in the opposite direction to the first layer.

[0007] Additionally, the winding may include a third layer wound in both directions along the circumference of the core from the first point toward the second point on the second layer.

[0008] In addition, the winding may include a first layer in which a first winding line is wound around the core in a clockwise direction from a first point of the core to a second point opposite to the first point, and a second layer in which the first winding line is wound around the core in a counterclockwise direction from the second point to the first point, and the second winding line is wound around the core in a clockwise direction, wherein the first winding line may be a line extending in one end direction of the winding, and the second winding line may be a line extending in the other end direction of the winding.

[0009] Additionally, the winding may include a third layer in which the first winding line winds the core in a clockwise direction from the first point to the second point, and the second winding line winds the core in a counterclockwise direction.

[0010] Additionally, the inductor may be molded, at least in part, within the housing.

[0011] Additionally, the inductor may have at least another portion exposed outside the molding.

[0012] Additionally, the inductor may be arranged and erected within the housing in a first direction perpendicular to the axial direction of the core, and may be molded within a range of 20 to 80% of the height in the first direction.

[0013] Additionally, the number of times the core is wound in the first layer may be different from the number of times the core is wound in the second layer.

[0014] Additionally, the inductor may include a plurality of inductors.

[0015] In order to solve the above technical problem, an inductor module according to an embodiment of the present invention includes a housing forming an internal space; and one or more inductors disposed inside the housing, wherein the inductor includes a core and a winding wound around the core, and at least a portion of the inductor may be molded inside the housing, and at least another portion may be exposed outside the molding.

[0016] Additionally, the inductor may be arranged and erected within the housing in a first direction perpendicular to the axial direction of the core, and may be molded within a range of 20 to 80% of the height in the first direction.

[0017] In addition, the winding includes a plurality of layers wound around the core, and the first layer and the second layer of the plurality of layers may have opposite winding directions around the core.

[0018] Additionally, the winding may include a first layer wound in both directions along the circumference of the core from a first point of the core toward a second point opposite to the first point; and a second layer wound on the first layer from the second point toward the first point along the circumference of the core in the opposite direction to the first layer.

[0019] According to embodiments of the present invention, unintended parasitic capacitance occurring during inductor manufacturing can be reduced. The spike in current flowing in the inductor during the IGBT switching turn-on / off of the boost circuit can be reduced, and the volume and size can be reduced due to a reduced amount of molding liquid injected.

[0020] FIG. 1 illustrates an inductor module according to one embodiment of the present invention.

[0021] Figures 2 and 3 illustrate an inductor module according to an embodiment of the present invention.

[0022] FIG. 4 illustrates a method for winding an inductor of an inductor module according to an embodiment of the present invention.

[0023] FIG. 5 and FIG. 6 are drawings for explaining molding of an inductor module according to an embodiment of the present invention.

[0024] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0025] However, the technical idea of ​​the present invention is not limited to some of the embodiments described, but can be implemented in various different forms, and within the scope of the technical idea of ​​the present invention, one or more of the components between the embodiments can be selectively combined or substituted for use.

[0026] In addition, terms (including technical and scientific terms) used in the embodiments of the present invention may be interpreted as having a meaning that can be generally understood by a person of ordinary skill in the technical field to which the present invention belongs, unless explicitly and specifically defined and described, and terms that are commonly used, such as terms defined in a dictionary, may be interpreted in consideration of the contextual meaning of the relevant technology.

[0027] Additionally, the terms used in the embodiments of the present invention are intended to describe the embodiments and are not intended to limit the present invention.

[0028] In this specification, the singular may also include the plural unless specifically stated otherwise in the phrase, and when it is described as “A and / or at least one (or more) of B, C”, it may include one or more of all combinations that can be combined with A, B, C.

[0029] Additionally, in describing components of embodiments of the present invention, terms such as first, second, A, B, (a), (b), etc. may be used. These terms are only intended to distinguish the components from other components, and are not intended to limit the nature, order, or sequence of the components.

[0030] And, when a component is described as being 'connected', 'coupled', or 'connected' to another component, it may include not only cases where the component is 'connected', 'coupled', or 'connected' directly to the other component, but also cases where the component is 'connected', 'coupled', or 'connected' by another component between the component and the other component.

[0031] Additionally, when described as being formed or arranged "above" or "below" each component, "above" or "below" includes not only cases where the two components are in direct contact with each other, but also cases where one or more other components are formed or arranged between the two components. Furthermore, when expressed as "above" or "below," the meaning may include not only the upward direction but also the downward direction based on one component.

[0032] FIG. 1 illustrates an inductor module according to one embodiment of the present invention.

[0033] FIGS. 2 to 3 illustrate an inductor module according to an embodiment of the present invention, FIG. 4 illustrates a method for winding an inductor of an inductor module according to an embodiment of the present invention, and FIGS. 5 and 6 are drawings for explaining molding of an inductor module according to an embodiment of the present invention.

[0034] An inductor module according to an embodiment of the present invention accommodates an inductor therein. An inverter module according to an embodiment of the present invention, in which an inductor module according to an embodiment of the present invention is mounted, may be a PV inverter module. A PV inverter module is a device that receives power from a PV panel or a PV converter and converts it into power that can be used in a home or building. It receives DC power such as a PV converter, converts it into AC power, and outputs it. At this time, the DC power is transmitted to an inverter driving unit through a wire connection, the inverter driving unit converts the power, and then transmits the converted power to a load again through the wire connection. The inverter driving unit may include a power conversion element and a switching element or an MCU for controlling the power conversion element. The power conversion element may include a passive element such as an inductor or a capacitor, and may include a switching element implemented as a FET or a diode, and may include an MCU for controlling the switching element. In addition, various elements for converting power may be included, or elements for implementing functions other than power conversion may be included.

[0035] An inductor module according to an embodiment of the present invention includes a housing (110) and an inductor (120).

[0036] The housing (110) forms an internal space (111) that accommodates an inductor (120). The housing (110) may include a base and a side plate extending from the base. The inductor (120) may be accommodated within the internal space (111) formed by the base and the side plate.

[0037] The inductor (120) is placed inside the housing (110). The inductor (120) may include one or more inductors, and may include multiple inductors depending on the characteristics of the boost circuit of the inverter module to which the inductor module is applied. It may include multiple inductors applied to a non-isolated DC-DC boost circuit. For example, it may include four inductors. The inductor (120) may include an inductor connected to the input terminals of multiple solar modules, and may include an inductor of a power conversion module or a grid-side inductor. In addition, it may include various inductors. The housing (110) includes respective receiving portions corresponding to the multiple inductors, and each inductor or inductors of the same type may be placed inside the housing (110) separately from other inductors.

[0038] When the inductor (120) is placed in the internal space (111) of the housing (110), it can be placed upright inside the housing (110) in a first direction perpendicular to the axial direction of the core (121) of the inductor, as shown in FIGS. 1 to 3. When a plurality of inductors are placed, for example, when four inductors are placed, they can be placed in a row, and the lead wires connected to each inductor can extend from each inductor and be connected to the outside of the housing (110).

[0039] The inductor (120) includes a core (121) and windings (124, 125) wound around the core (121). The core (121) has a cylindrical shape with a hole in the center, and the core (121) may be formed of metal. The inductor (120) is formed by winding the core (121) with windings (124, 125) along the circumference of the core. At this time, winding the windings (124, 125) around the core (121) is called winding. The number of windings (124, 125) wound around the core (121) is called the number of turns. The windings (124, 125) may include multiple layers wound around the core (121) according to the required number of turns. The winding (124, 125) can be wound not once around the core (121) but doubled, tripled, or more times to form multiple layers to achieve the required number of turns. For example, it can include two layers or three or more layers, and can be wound in three layers to achieve 63 turns.

[0040] When implementing windings in multiple layers, unintended parasitic capacitances may occur due to voltage differences between winding coils, and spike noise currents may occur during other circuit switching operations due to parasitic capacitances.

[0041] To solve this problem, the windings (124, 125) are wound in multiple layers around the core (121), but the first and second layers of the multiple layers may be wound in opposite directions. When winding the windings (124, 125) around the core (121), instead of winding in only one direction, the winding directions of the first and second layers may be opposite to each other.

[0042] The windings (124, 125) may include a first layer (126) wound in both directions along the circumference of the core (121) from a first point (122) of the core (121) toward a second point (123) opposite to the first point (122), and a second layer (127) wound in the opposite direction to the first layer (126) along the circumference of the core (121) from a second point (123) toward the first point (122) on the first layer (126). The starting point of the windings (124, 125) may start from the first point (122) of the core (121). Both winding lines of the windings (124, 125) may be wound from the first point (122) in a direction toward the second point (123). The first layer (126) can be formed by winding from the first point (122) to the second point (123). The number of windings in both directions can be the same. Since the core (121) has a cylindrical shape, the centers of the cores (121) can be wound so that they touch each other, and the outer edges of the cores (121) can be arranged so that they are spaced apart from each other.

[0043] When the entire circumference of the core (121) is wound to form the first layer (126), it becomes the second point, and the second layer (127) can be started from the second point (123). When winding the second layer (127), it can be wound in the opposite direction to the winding direction of the first layer (126). That is, the lines extending from the first layer and winding the second layer can overlap with the corresponding lines wound on the first layer. The two lines extending from the first point (122), which is the center of winding the windings (124, 125), do not overlap each other in the height direction of the layer. Through this, the entire area of ​​the core (121) can be divided in half, and layers can be formed in the first half area and the second half area, respectively, to wind the windings (124, 125).

[0044] The coil (124, 125) includes a third layer (128), and the third layer (128) can be wound in both directions along the circumference of the core (121) from the first point (122) toward the second point (123) on the second layer (127). The third layer (128) can be formed by winding the core (121) in the opposite direction to the second layer (127) and in the same direction as the first layer (126).

[0045] When implementing more than 4 layers, additional layers may be added while crossing the winding direction.

[0046] The number of turns (124, 125) around the core (121) in the first layer (126) may be different from the number of turns around the core (121) in the second layer (127). By winding the first layer (126), the diameter of the hole of the core (121) is reduced by the thickness of the turns (124, 125), and the number of turns that can be made around the second layer (127) is reduced. As the number of layers increases, the number of turns (124, 125) that can be made decreases, and when all the holes of the core (121) are filled with the turns (124, 125), the turns may no longer be wound.

[0047] The windings (124, 125) may include a first layer (126) in which the first winding line (124) winds the core (121) clockwise from a first point (122) of the core (121) toward a second point (123) opposite to the first point (122), and a second layer (127) in which the first winding line (124) winds the core (121) counterclockwise from the second point (123) toward the first point (122), and the second winding line (125) winds the core (121) clockwise. Here, the first winding line (124) may be a line extending in one end direction of the winding, and the second winding line (125) may be a line extending in the other end direction of the winding.

[0048] As shown in Fig. 4, the winding starting from the first point of the core (121) includes a first winding line (124) and a second winding line (125) extending in both directions, and the first winding line (124) can be wound around the core (121) in a clockwise direction, and the second winding line (125) can be wound around the core (121) in a counterclockwise direction to form a first layer (126). After winding to the second point (123) to form the first layer (126), the first winding line (124) can be wound around the core (121) in a counterclockwise direction on the first layer (126), and the second winding line (125) can be wound around the core (121) in a clockwise direction to form a second layer (127).

[0049] In addition, the windings can form a third layer (128) by winding the core (121) clockwise with the first winding line (124) from the first point (122) to the second point (123) and winding the core counterclockwise with the second winding line (125). In this way, the first winding line (124) and the second winding line (125) can each be wound in a split winding to wind the core (121) in multiple layers. In this way, parasitic capacitance can be reduced by forming an inductor through split winding.

[0050] The inductor (120) disposed in the internal space of the housing (110) may be molded at least partially inside the housing (110). Since the inductor (120) generates a lot of heat, for heat dissipation, after the inductor (120) is disposed inside the housing (110), at least a portion of the inductor (120) may be molded with a molding liquid (130). In order to increase the heat dissipation effect during molding, when molding with a molding liquid (130) containing a metal component, the permittivity of the metal component of the molding liquid may combine with the winding, thereby increasing parasitic capacitor. To solve this problem, instead of molding the entire inductor (120), a portion of the inductor (120) may be exposed to the outside of the molding.

[0051] The inductor (120) is placed and erected inside the housing (110) in a first direction perpendicular to the axial direction of the core (121), and can be molded within a range of 20 to 80% of the height in the first direction. As shown in Fig. 7, the molding liquid (130) can be molded to a height D2 for the height D1 of the core (121) of the inductor (120) in the first direction, and D2 can be 20 to 80% of D1.

[0052] To improve the heat dissipation effect of the molding and reduce parasitic capacitors, the inductor (120) can be molded within the range of 20 to 80%. When molding is 20%, the parasitic capacitor can increase by up to 10%, when molding is 50%, it can increase by up to 30%, and when molding is 80%, it can increase by up to 50%. However, as the molding amount decreases, the inductor heat dissipation performance decreases, so the molding volume must be maintained at least 20% to maintain the heat dissipation performance.

[0053] An inductor module according to an embodiment of the present invention includes a housing (110) forming an internal space and one or more inductors (120) disposed inside the housing (110), wherein the inductor (120) includes a core (121) and windings (124, 125) wound around the core (121), and at least a portion of the inductor (120) may be molded inside the housing, and at least another portion may be exposed to the outside of the molding. In addition, the inductor (120) may be disposed upright inside the housing (110) in a first direction perpendicular to the axial direction of the core (121), and may be molded within a range of 20 to 80% of the height in the first direction. In addition, the winding (124, 125) includes a plurality of layers wound around the core (121), and the first layer (126) and the second layer (127) of the plurality of layers may be wound in opposite directions around the core (121), and the first layer (126) may be formed by winding in both directions along the circumference of the core (121) from the first point (122) of the core (121) toward the second point (123) opposite to the first point (122), and the second layer (127) may be formed by winding along the circumference of the core (121) from the second point (123) toward the first point (122) on the first layer (126) in the opposite direction to the first layer (126).

[0054] As described above, parasitic capacitance can be reduced through split winding and partial molding. The parasitic capacitance according to the winding method and molding is as follows.

[0055]

[0056] In the case of a conventional winding that is wound only in one direction, rather than a split winding, if not molded, it has a parasitic capacitance of 140 pF, and if molded, the parasitic capacitance increases to 830 pF. When using a split winding, it can be confirmed that the parasitic capacitance is reduced to 27.6 pF, and when partial molding is performed for heat dissipation, the parasitic capacitance increases to 32.6 pF, but the increase is confirmed to be reduced. It can be confirmed that the parasitic capacitance of 830 pF is reduced to 27.6 pF through the split winding and partial molding. As described above, the unintended parasitic capacitance that occurs during inductor manufacturing can be reduced through the split winding and partial molding. The spike of current flowing in the inductor when the IGBT switching of the boost circuit is turned on and off can be reduced, and the volume and size can be reduced due to a decrease in the amount of molding liquid injected.

[0057] An inverter module according to an embodiment of the present invention may include an inductor module of FIGS. 1 to 7. The inverter module may include a case in which components are arranged, a cover covering the case, and an inductor module. A detailed description of the inductor module included in the inverter module corresponds to the detailed description of the inductor module of FIGS. 1 to 7, and thus, any duplicate description will be omitted below. The case may form an internal space in which components of the inverter module are arranged, and an inverter drive unit and a wire connection unit may be arranged. Here, the inverter drive unit may be a drive unit of a 7.6 kW inverter or an 11.4 kW inverter module.

[0058] As described above, the present invention has been described with specific details such as specific components and limited examples and drawings, but these are provided only to help a more general understanding of the present invention, and the present invention is not limited to the above examples, and those with ordinary knowledge in the field to which the present invention pertains can make various modifications and variations from this description.

[0059] Therefore, the idea of ​​the present invention should not be limited to the described embodiments, and all things that are equivalent or equivalent to the following claims as well as the claims are considered to fall within the scope of the idea of ​​the present invention.

Claims

1. A housing forming an internal space; and comprising one or more inductors disposed inside the housing; The above inductor, It includes a core and a winding wound around the core, The above winding is, comprising a plurality of layers surrounding the core, An inductor module in which the first and second layers of the above multiple layers have cores wound in opposite directions.

2. In paragraph 1, The above winding is, A first layer wound in both directions along the circumference of the core from a first point of the core to a second point opposite to the first point; and An inductor module comprising a second layer wound in the opposite direction to the first layer along the circumference of the core from the second point toward the first point on the first layer.

3. In paragraph 2, The above winding is, An inductor module comprising a third layer wound in both directions along the circumference of the core from the first point toward the second point on the second layer.

4. In paragraph 1, The above winding is, A first layer in which a first winding line winds the core clockwise from a first point of the core to a second point opposite to the first point, and a second winding line winds the core counterclockwise; and From the second point to the first point, the first winding line includes a second layer that winds the core in a counterclockwise direction, and the second winding line includes a second layer that winds the core in a clockwise direction. The above first winding line is a line extending in one direction of the above winding, The above second winding line is an inductor module that extends in the other end direction of the above winding.

5. In paragraph 4, The above winding is, An inductor module including a third layer in which the first winding line winds the core clockwise from the first point to the second point, and the second winding line winds the core counterclockwise.

6. In paragraph 1, The above inductor, An inductor module at least partially molded inside a housing.

7. In paragraph 6, The above inductor, An inductor module in which at least some of the other parts are exposed outside the molding.

8. In paragraph 6, The above inductor It is arranged and erected inside the housing in a first direction perpendicular to the axial direction of the core, An inductor module molded within a range of 20 to 80% of the height in the first direction.

9. In paragraph 1, The above winding is An inductor module in which the number of turns of the core in the first layer is different from the number of turns of the core in the second layer.

10. In paragraph 1, The above inductor is an inductor module including a plurality of inductors.

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