Coil unit, coil winding and magnetic component

Abstract

The present application relates to the technical field of coils, and specifically relates to a coil unit, a coil winding, and a magnetic component. The coil unit comprises a plurality of planar coils formed by winding strip conductors; each planar coil comprises a coil body, and a first connection segment and a second connection segment which are connected to two ends of the coil body in a winding direction; the plurality of planar coils are stacked in the thickness direction of the strip conductors; each two adjacent planar coils are spaced apart to form a heat dissipation channel. By means of the heat dissipation channels, the heat exchange coefficient of the coil unit, the coil winding and the magnetic component can be increased, thereby reducing temperature rises. The first connection segments of all the planar coils are connected, and the second connection segments of all the planar coils are connected, so as to reduce the skin effect and the resistance of the coil unit while ensuring good contact between end portions of the multi-layer planar coils, thereby reducing the loss of coil windings and magnetic components, and helping to improve the reliability of the coil windings and the magnetic components.

Description

A coil unit, a coil winding, and a magnetic element Technical Field

[0001] This application relates to the field of coil technology, specifically to a coil unit, coil winding, and magnetic element. Background Technology

[0002] Magnetic components are essential power electronic devices for energy storage, energy conversion, and electrical isolation. Magnetic components mainly include inductors and transformers, and typically consist of coil windings and magnetic cores.

[0003] Current power supply circuits not only require magnetic components to be smaller and smaller, but also require them to have high efficiency, low loss, and low temperature rise characteristics. As an important component of magnetic components, coil windings generate high losses and temperature rises during operation, especially at high frequencies. Due to the skin effect on the conductor surface, the losses of the coil windings increase, resulting in higher temperatures for the magnetic components. On the other hand, the heat dissipation of magnetic components is also limited within a confined space. Therefore, magnetic components are prone to aging, thermal fatigue, and even failure at high temperatures.

[0004] Summary of the Invention

[0005] This application provides a coil unit, a coil winding, and a magnetic element to solve the technical problem that high coil winding losses and temperature rise in magnetic elements can easily lead to magnetic element failure.

[0006] According to a first aspect, one embodiment provides a coil unit including a plurality of sheet coils formed by winding strip wire. Each sheet coil includes a coil body, a first connecting segment, and a second connecting segment. The first connecting segment and the second connecting segment are respectively connected to both ends of the coil body in the winding direction. The plurality of sheet coils are stacked in the thickness direction of the strip wire. Adjacent sheet coils are spaced apart to form a heat dissipation channel. The first connecting segments of all sheet coils are connected, and the second connecting segments of all sheet coils are connected.

[0007] In one optional embodiment, the winding axis of the coil body is in the same direction as the thickness direction of the strip wire; or, the winding axis of the coil body is in the same direction as the width direction of the strip wire.

[0008] In one alternative embodiment, the coil body has an open-loop structure, and the strip wire is wound once to form the coil body.

[0009] In one optional embodiment, the winding axis of the coil body is in the same direction as the thickness direction of the strip wire, and the dimension of the coil body in the winding axis direction is equal to the thickness dimension of the strip wire; or, the winding axis of the coil body is in the same direction as the width direction of the strip wire, and the dimension of the coil body in the winding axis direction is equal to the width dimension of the strip wire.

[0010] In one alternative embodiment, the first connecting segment and the second connecting segment are arranged at intervals in the winding direction of the coil body;

[0011] The winding axis of the coil body is in the same direction as the thickness direction of the strip wire, and the size of the sheet coil in the direction of the winding axis is equal to the thickness of the strip wire; or, the winding axis of the coil body is in the same direction as the width direction of the strip wire, and the size of the sheet coil in the direction of the winding axis is equal to the width of the strip wire.

[0012] In one optional embodiment, the orientation of the first connecting segment is opposite to that of the second connecting segment; or, the orientation of the first connecting segment is the same as that of the second connecting segment, and the first connecting segment and the second connecting segment are arranged at intervals.

[0013] In one alternative embodiment, the first connecting segment has a first connecting end and a first suspension end located at both ends thereto, the first connecting end being connected to the coil body, and two adjacent first suspension ends being connected in the thickness direction of the strip wire; and / or,

[0014] The second connecting segment has a second connecting end and a second suspension end located at both ends thereto. The second connecting end is connected to the coil body, and two adjacent second suspension ends are connected in the thickness direction of the strip wire.

[0015] In an alternative embodiment, in the thickness direction of the strip wire, two adjacent first connecting segments are connected by a solder layer, and / or two adjacent second connecting segments are connected by a solder layer.

[0016] In one alternative embodiment, the surface of the sheet coil is coated with an anti-oxidation layer.

[0017] In one alternative embodiment, the coil unit includes a support structure located between two adjacent coil bodies in the thickness direction of the strip wire, such that a predetermined gap forms the heat dissipation channel between the two adjacent coil bodies.

[0018] According to a second aspect, one embodiment provides a coil winding comprising a plurality of coil units as described in any of the preceding claims, wherein the winding axes of all the coil units are coaxial, adjacent two coil units are arranged in the winding direction of the coil units and / or in the direction of the winding axis, and all the coil units are connected in series and / or in parallel.

[0019] According to a third aspect, one embodiment provides a magnetic element, including a magnetic core, and further including any of the coil units or coil windings described above.

[0020] According to the above embodiments, the coil unit, coil winding, and magnetic element comprise a plurality of sheet coils formed by winding strip wire. Each sheet coil includes a coil body, a first connecting section, and a second connecting section. The first and second connecting sections are respectively connected to the two ends of the coil body in the winding direction. The plurality of sheet coils are stacked in the thickness direction of the strip wire, and adjacent sheet coils are spaced apart to form a heat dissipation channel. The heat dissipation channel can increase the heat transfer coefficient of the coil unit, the entire coil winding, and the magnetic element, thereby reducing the temperature rise. The first connecting sections of all sheet coils are connected, and the second connecting sections of all sheet coils are connected. Thus, the coil unit forms a multi-layer sheet structure arranged in parallel. While ensuring good contact at each end of the multi-layer sheet coils, it can reduce the resistance of the entire coil unit, thereby reducing the DC loss of the coil unit, the entire coil winding, and the magnetic element. Furthermore, the multi-layer sheet coil stacked structure can reduce the skin effect at high frequencies, thereby reducing the AC loss of the coil unit, the entire coil winding, and the magnetic element, and helping to improve the reliability of the coil winding and the magnetic element. Attached Figure Description

[0021] Figure 1 is a schematic diagram of the structure of a coil unit according to an embodiment;

[0022] Figure 2 is a schematic diagram of the structure of a coil unit in another embodiment;

[0023] Figure 3 is a schematic diagram of the structure of a coil unit in another embodiment;

[0024] Figure 4 is a structural schematic diagram of a coil unit in another embodiment;

[0025] Figure 5 is a partial exploded structural diagram of a prior art trans-inductance voltage regulator;

[0026] Figure 6 is a schematic diagram of the structure of an embodiment of an inductor regulator;

[0027] Figure 7 shows the temperature rise distribution of the external coil of the transinductance regulator in Figure 5 when a 50A DC current is applied to it.

[0028] Figure 8 shows the temperature rise distribution of the outer coil of the transinductance regulator in Figure 6 when a 50A DC current is applied.

[0029] In the diagram: 1. Sheet coil; 10. Heat dissipation channel; 11. Coil body; 12. First connecting section; 121. First connecting end; 122. First suspension end; 13. Second connecting section; 131. Second connecting end; 132. Second suspension end; 21. Outer magnetic core; 22. Middle core; 23. Outer coil; 24. Inner coil. Detailed Implementation

[0030] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments. Similar elements in different embodiments are referred to by related similar element reference numerals. In the following embodiments, many details are described to facilitate a better understanding of the present application. However, those skilled in the art will readily recognize that some features may be omitted in different situations, or may be replaced by other elements, materials, or methods. In some cases, certain operations related to the present application are not shown or described in the specification. This is to avoid obscuring the core parts of the present application with excessive description. For those skilled in the art, detailed description of these related operations is not necessary; they can fully understand the related operations based on the description in the specification and general technical knowledge in the art.

[0031] Furthermore, the features, operations, or characteristics described in the specification can be combined in any suitable manner to form various embodiments, and the operational steps involved in each embodiment can also be rearranged or adjusted in a manner that is obvious to those skilled in the art. Therefore, the specification and drawings are only for clearly describing a particular embodiment and do not imply that they represent the necessary components and / or order.

[0032] The serial numbers assigned to components in this document, such as "first" and "second," are used only to distinguish the described objects and have no sequential or technical meaning. The terms "connection" and "linkage" used in this application, unless otherwise specified, include both direct and indirect connections (linkages).

[0033] This application discloses a coil unit that can be used in coil windings or in magnetic components such as inductors or transformers to reduce losses and temperature rise in coil windings and magnetic components, thereby reducing the probability of coil winding failure and improving the reliability of coil windings and magnetic components.

[0034] The coil unit disclosed in this application embodiment, as shown in Figures 1 to 4, includes multiple sheet coils 1. The sheet coil 1 is formed by winding strip wire. The strip wire is wound along its length direction, and the width dimension of the strip wire is much larger than its thickness dimension, so that the rolled strip wire has a sheet structure.

[0035] The sheet coil 1 includes a coil body 11, a first connecting section 12, and a second connecting section 13. In some embodiments, referring to FIG1, the winding axis of the coil body 11 is in the same direction as the width direction of the strip wire, that is, the strip wire is bent in its length and thickness directions. In other embodiments, referring to FIG2 to FIG4, the winding axis of the coil body 11 is in the same direction as the thickness direction of the strip wire, that is, the strip wire is bent in its length and width directions.

[0036] In some embodiments, please continue to refer to Figures 2 to 4, the strip coil is wound to form the coil body 11, and the structure enclosed by the coil body 11 can be circular, elliptical, or rectangular; of course, in other embodiments, the structure enclosed by the coil body 11 can also be trapezoidal, triangular, or other irregularly shaped structures. The shape of the structure enclosed by the coil body 11 matches the cross-sectional shape of the magnetic core around which the coil body 11 is surrounded, and the shape of the structure enclosed by the coil body 11 depends on the cross-sectional shape of the magnetic core around which the coil body 11 is surrounded.

[0037] In some embodiments, please refer to Figures 1 to 4. The coil body 11 has an open-loop structure. The strip wire is wound around to form the coil body 11, which does not mean that the two ends of the coil body 11 are in contact in its winding direction. In embodiments where the shape of the coil body 11 enclosing structure is circular, the central angle corresponding to the coil body 11 in its winding direction is approximately 270°, which means that the strip wire corresponding to the coil body 11 is wound three-quarters of a turn. Since the coil body 11 formed by the strip wire being wound three-quarters of a turn can meet the requirements of magnetic field change after the coil body 11 is energized, the strip wire being wound three-quarters of a turn can be considered as the strip wire being wound one turn. In embodiments where the shape of the coil body 11 is trapezoidal, rectangular, or other irregularly shaped, the central angle corresponding to the coil body 11 can be understood as the angle between the two ends of the coil body 11 and the geometric center of the enclosing shape of the coil body 11. This angle is directed towards the coil body 11. As long as the angle is within the range of 270° to 360°, the strip wire corresponding to the coil body 11 can be considered as being wound one turn.

[0038] In other embodiments, the strip wire corresponding to the coil body 11 can be wound half a turn or one-third turn. When the coil body 11 is used in the coil winding or magnetic element, it is necessary to set an external wire or coil to ensure that the central angle of the structure formed by the coil body 11 and the external wire or the coil is greater than 270°, so that the coil winding meets the magnetic field change requirements when energized.

[0039] Of course, in some other embodiments, the number of turns of the strip wire corresponding to the coil body 11 can be greater than one turn, such as the strip wire being wound one and a half turns, or two or three or more turns to form the coil body 11.

[0040] In some embodiments, referring to Figure 1, a strip of wire is wound once to form a coil body 11, and the direction of the winding axis of the coil body 11 is in the same direction as the width direction of the strip of wire. The dimensions of the coil body 11 are equal everywhere in the direction of the winding axis, and the dimensions of the coil body 11 in the direction of the winding axis are equal to the width dimension of the strip of wire. That is, the strip of wire is wound in a plane perpendicular to its width direction to form the coil body 11. The coil body 11 is wound in the plane, and the two ends of the coil body 11 in its winding direction are positioned in the direction of the winding axis, so as to facilitate the processing and manufacturing of the coil body 11.

[0041] In some other embodiments, referring to Figures 2 to 4, a strip of wire is wound once to form a coil body 11, and the direction of the winding axis of the coil body 11 is in the same direction as the thickness direction of the strip of wire. The size of the coil body 11 is equal everywhere in the direction of the winding axis, and the size of the coil body 11 in the direction of the winding axis is equal to the thickness of the strip of wire. That is, the strip of wire is wound in a plane perpendicular to its thickness direction to form a sheet coil 1 composed of the coil body 11, the first connecting segment 12 and the second connecting segment 13 to form the coil body 11. The coil body 11 is wound in a plane, and the two ends of the coil body 11 in its winding direction are positioned in the direction of the winding axis, which also facilitates the processing and manufacturing of the coil body 11.

[0042] Of course, in other embodiments, regardless of whether the strip wire forming the coil body 11 is wound one turn, less than one turn, or more turns, and regardless of whether the winding axis of the coil body 11 is in the same direction as the width direction or the thickness direction of the strip wire, the coil body 11 can be wound in a plane, that is, the two ends of the coil body 11 in its winding direction are positioned in the direction of the winding axis; or the coil body 11 can be wound in a spiral shape, with the two ends of the coil body 11 in its winding direction staggered in the direction of the winding axis.

[0043] In the sheet coil 1, the first connecting segment 12 and the second connecting segment 13 are respectively connected to the two ends of the coil body 11 in the winding direction. Referring to Figures 1 to 4, the first connecting segment 12 and the second connecting segment 13 can be arranged at intervals in the winding direction of the coil body 11 to avoid short-circuiting at both ends of the coil body 11 and to facilitate the connection of both ends of the coil body 11 to external wires or coils.

[0044] In some embodiments, referring to FIG1, the winding axis of the coil body 11 is in the same direction as the width direction of the strip wire, and the size of the sheet coil 1 in the winding axis direction is equal to the width of the strip wire. That is, in the winding axis direction, the size of the sheet coil 1 composed of the coil body 11, the first connecting section 12 and the second connecting section 13 is equal to the width of the strip wire. The entire sheet coil 1 is formed by winding in a plane perpendicular to the width direction of the strip wire, so as to facilitate the winding of the entire strip wire.

[0045] In other embodiments, referring to Figures 2 to 4, the winding axis of the coil body 11 is in the same direction as the thickness direction of the strip wire. The size of the sheet coil 1 in the direction of the winding axis is equal to the thickness of the strip wire. That is, in the direction of the winding axis, the size of the sheet coil 1, composed of the coil body 11, the first connecting segment 12, and the second connecting segment 13, is equal to the thickness of the strip wire. The entire sheet coil 1 is formed by winding in a plane perpendicular to the thickness direction of the strip wire, which facilitates the winding of the entire sheet coil 1. Of course, in other embodiments, it is also possible to limit the winding of the coil body 11 to a plane perpendicular to the width or thickness direction of the strip wire, and the angle between the extension direction of the first connecting segment 12 and / or the second connecting segment 13 and the direction of the winding axis is less than 90°. This facilitates the connection of two adjacent sheet coils 1 in the direction of the winding axis.

[0046] Please refer to Figures 1 to 4. The first connecting segment 12 has a first connecting end 121 and a first suspension end 122 located at both ends of the segment. The first connecting end 121 is connected to the coil body 11. The second connecting segment 13 has a second connecting end 131 and a second suspension end 132 located at both ends of the segment. The second connecting end 131 is connected to the coil body 11. The orientation of the first connecting segment 12 is the direction from the first connecting end 121 to the first suspension end 122. The orientation of the second connecting segment 13 is the direction from the second connecting end 131 to the second suspension end 132.

[0047] In some embodiments, please continue to refer to Figures 1 to 3. The sheet coil 1 is wound in a plane perpendicular to the winding axis. The coil body 11 is wound one turn or less. The first connecting segment 12 and the second connecting segment 13 are arranged at intervals in the winding direction of the coil body 11. The first connecting segment 12 and the second connecting segment 13 have the same orientation, and the orientation of the first connecting segment 12 is away from the structure enclosed by the coil body 11. Alternatively, the orientations of the first connecting segment 12 and the second connecting segment 131 may be different. For example, the orientation of the first connecting segment 12 may be opposite to the orientation of the second connecting segment 13. This facilitates the connection between two adjacent coil units in the direction of the winding axis or the connection between a coil unit and other wires or coils.

[0048] In other embodiments, in a structure in which only the coil body 11 is wound in a plane perpendicular to the winding axis, the first connecting segment 12 and the second connecting segment 13 may also face one or both sides of the winding axis, or the orientation of the first connecting segment 12 and / or the second connecting segment 13 may have an angle of less than 90° with the winding axis. This also facilitates the electrical connection between the coil unit and coil units, wires or coils arranged at intervals in the winding axis direction.

[0049] In other embodiments, the coil body 11 is wound in a spiral shape. The coil body 11 may be wound one turn, less than one turn, or multiple turns. The first connecting segment 12 and the second connecting segment 13 may be arranged at intervals in the direction of the winding axis. The first connecting segment 12 and the second connecting segment 13 have the same orientation, which also facilitates the electrical connection between the coil unit and the wires or coils arranged at intervals in the direction of the winding axis.

[0050] Of course, in other embodiments, regardless of whether the coil body 11 is wound in a plane perpendicular to the direction of the winding axis, and regardless of whether the coil body 11 is wound one turn, less than one turn, or more turns, as long as the first connecting segment 12 and the second connecting segment 13 are arranged at intervals and the first connecting segment 12 and the second connecting segment 13 are not short-circuited.

[0051] In this embodiment, the coil unit contains multiple sheet coils 1, which are stacked in the thickness direction of the strip wire. This structure reduces the skin effect of the entire coil unit, thereby reducing the AC loss of the coil unit. In some embodiments, referring to Figure 1, the winding axis of the coil body 11 is in the same direction as the width direction of the strip wire. The multiple sheet coils 1 are arranged in a direction that gradually moves away from the winding axis of the coil body 11. This requires that the winding radius of the coil body 11 farther from the winding axis is slightly larger than that of the coil body 11 closer to the winding axis. In order to ensure that the end faces of the first suspension ends 122 and the second suspension ends 132 of the multiple sheet coils 1 are flush, so as to facilitate the connection between the coil unit and adjacent coil units, wires or coils, the length of the sheet coil 1 farther from the winding axis, that is, the length of the strip wire, is also required to be slightly larger than the length of the sheet coil 1 closer to the winding axis.

[0052] In other embodiments, referring to Figures 2 to 4, the winding axis of the coil body 11 is in the same direction as the thickness direction of the strip wire. The dimensions between the stacked sheet coils 1 and the winding axis of the coil body 11 are all equal. Thus, the winding radius and length of each coil body 11 are equal. This facilitates the processing and manufacturing of each sheet coil 1 in the coil unit, helps to reduce the processing accuracy requirements of each sheet coil 1, and also helps to reduce the resistance of the coil unit, thereby reducing the loss of the coil unit.

[0053] To facilitate the connection between the coil unit and other wires or coils, a first connecting segment 12 is provided for each sheet coil 1 in the coil unit, and a second connecting segment 13 is provided for each sheet coil 1. Specifically, referring to Figures 1 to 4, two adjacent second suspension ends 132 are connected in the thickness direction of the strip wire, and two adjacent first suspension ends 122 are connected. While ensuring that multiple first suspension ends 122 and multiple second suspension ends 132 are connected respectively, the resistance of the entire coil unit can be reduced by the parallel arrangement of the sheet coils 1, thereby reducing the DC loss of the coil unit. Of course, in other embodiments, the specific connection positions of the multiple first connecting segments 12 and multiple second connecting segments 13 are not limited. The multiple first connecting segments 12 can be connected at any position between the first connecting end 121 and the first suspension end 122, and the multiple second connecting segments 13 can be connected at any position between the second connecting end 131 and the second suspension end 132.

[0054] In addition, multiple stacked sheet coils 1 are arranged with intervals between adjacent sheet coils 1 to form a heat dissipation channel 10 between adjacent sheet coils 1. The heat dissipation channel 10 can also increase the heat dissipation area of ​​the coil unit and increase the heat dissipation coefficient of the coil unit, thereby reducing the temperature rise of the coil unit.

[0055] In the stacked sheet coils 1, the distance between two adjacent sheet coils 1 is equal to improve the structural consistency of the entire coil unit. In some embodiments, during the connection of the first connecting segment 12 and the second connecting segment 13 of the multiple sheet coils 1, a cardboard can be placed between two adjacent sheet coils 1. After the multiple first connecting segments 12 and the multiple second connecting segments 13 are connected, the cardboard can be removed to form a preset gap between two adjacent sheet coils 1. The preset gap between two sheet coils 1 forms a heat dissipation channel 10 between two adjacent sheet coils 1. The preset gap size needs to be sufficient to allow airflow, and the preset gap size can be equal to the thickness of the cardboard.

[0056] In other embodiments, the coil unit includes a support structure located between two adjacent coil bodies 11 in the thickness direction of the strip wire, that is, between two adjacent sheet coils 1 in the stacking direction of the plurality of sheet coils 1, so that there is a preset gap between the two adjacent coil bodies 11 to form a heat dissipation channel 10. The size of the preset gap can be guaranteed by the size of the support structure in the stacking direction of the plurality of sheet coils 1.

[0057] In one embodiment, the support structure may include a dotted adhesive layer, which is an insulating adhesive layer. Multiple dotted adhesive layers are provided between two adjacent sheet coils 1. These multiple dotted adhesive layers are spaced apart in a plane perpendicular to the winding axis. It is important to note that the area of ​​each dotted adhesive layer should not be too large, and the number of dotted adhesive layers should not be excessive. The multiple dotted adhesive layers ensure that the gap between two adjacent sheet coils 1 is equal at all points. The spaced arrangement of adjacent dotted adhesive layers forms a heat dissipation channel 10 between them. The dotted adhesive layer can be fixedly connected to one of the sheet coils 1 by adhering the dotted adhesive to it.

[0058] In other embodiments, the support structure may also include an insulating block, which is adhered to one of two adjacent sheet coils 1 by adhesive. There are multiple insulating blocks, and adjacent insulating blocks are arranged at intervals. The size of the insulating block in the direction of the winding axis is equal to the preset gap size between the two adjacent sheet coils 1. A heat dissipation channel 10 is formed between the two adjacent insulating blocks, and the preset gap between the two adjacent sheet coils 1 is ensured by the insulating block.

[0059] To avoid short circuits between two adjacent coil bodies 11 in the direction of the winding axis, thereby improving the stability and reliability of individual coils, the sheet coils 1 are insulated and anti-oxidation treated before multiple sheet coils 1 are connected in parallel. In some embodiments, an insulating layer can be coated on the surface of the sheet coil 1 to achieve the effects of insulation and anti-oxidation. When the current-carrying voltage is low, only the sheet coil 1 can be treated to prevent oxidation, such as by forming an anti-oxidation layer on the surface of the sheet coil 1 by electroplating or matte tinning.

[0060] In a plurality of stacked sheet coils 1, the first connecting segments 12 of two adjacent sheet coils 1 are connected by a solder layer, and two adjacent second connecting segments 13 are also connected by a solder layer. In one embodiment, in order to facilitate the connection of two adjacent sheet coils 1, it is also necessary to perform solderability treatment on the first connecting segments 12 and the second connecting segments 13 on each sheet coil 1. For example, after performing anti-oxidation and insulation treatment on the sheet coils 1, the insulating layer attached to the first suspension end 122 of the first connecting segment 12 and the second suspension end 132 of the second connecting segment 13 can be removed, and then the first suspension end 122 of the first connecting segment 12 and the second suspension end 132 of the second connecting segment 13 can be tin-plated, nickel-plated or silver-plated to form a solder layer, so as to facilitate the connection of two adjacent first connecting segments 12 and two adjacent second connecting segments 13 by welding through the solder layer, which helps to ensure the connection reliability of two adjacent sheet coils 1.

[0061] In embodiments where only anti-oxidation treatment of the sheet coil 1 is required and insulation treatment is not necessary, the entire sheet coil 1 can be treated with matte tinning or electroplating to ensure that the sheet coil 1 has an anti-oxidation effect while also ensuring that two adjacent first connecting segments 12 and two adjacent second connecting segments 13 are connected by a solder layer.

[0062] This application also discloses a coil winding comprising multiple coil units as described in any of the above embodiments, with the winding axes of all coil bodies 11 being coaxial. In embodiments where the coil body 11 of a coil unit is wound less than one turn, multiple coil units are first connected in series to form a one-turn structure, and then connected in series with the remaining multiple coil units that form a one-turn structure to form a coil winding with multiple turns. Thus, adjacent coil units are arranged in the winding direction of the coil body 11, and adjacent coil units are also spaced apart in the direction of the winding axis of the coil body 11.

[0063] In an embodiment where the coil body 11 is wound less than one turn in a single coil unit and multiple coil units are connected in series in the winding direction to form a complete turn structure, multiple coil units are connected in series to form a single-turn coil winding, so that adjacent two coil units are arranged only in the winding direction of the coil body 11.

[0064] In embodiments where the number of turns of the coil body 11 in a single coil unit is greater than one turn, multiple coil units are arranged in the direction of the winding axis, and multiple coil units are connected in series to form a multi-turn coil winding.

[0065] In an embodiment where the coil body 11 is wound one turn in a single coil unit, multiple coil units are arranged in the direction of the winding axis, and multiple coil units can also be connected in parallel to form a single-turn coil winding.

[0066] The current flows in the same direction in each coil unit, from the first connecting section 12 to the second connecting section 13. Regardless of whether the coil units are arranged in the direction of the winding axis or in the winding direction of the coil body 11, when two adjacent coil units are connected in series, the first connecting section 12 of one coil unit is connected to the second connecting section 13 of the other coil unit; when two adjacent coil units are connected in parallel, the first connecting section 12 of one coil unit is connected to the first connecting section 12 of the other coil unit.

[0067] When two adjacent coil units arranged in series in the winding direction of the coil body 11, the first connecting section 12 of one coil unit and the second connecting section 13 of the other coil unit can be connected by a solder layer, i.e., welding. When two adjacent coil units arranged in parallel or in series in the direction of the winding axis of the coil body 11, a conductive post can be set between the two connecting sections to be connected, and the conductive post can be welded to the two connecting sections to be connected to achieve a conductive connection between the two connecting sections.

[0068] This application also discloses a magnetic element, which includes a magnetic core and a coil unit or coil winding as described in any of the above embodiments. The magnetic element can be one of the electrical components comprising a magnetic core and a coil, such as a transformer, inductor, magnetic memory, electromagnetic current collector, magnetic sensor, terrain filter, or current transformer.

[0069] In a magnetic element, a coil winding or a single coil unit is arranged around a magnetic core. The magnetic core may include an iron core. The direction of extension of the magnetic core is the direction of the winding axis of the coil body 11. The cross-sectional shape of the magnetic core determines the shape formed by the coil body 11 enclosing the coil winding or the single coil unit.

[0070] In embodiments where the magnetic element includes a magnetic core and a coil unit, the coil body 11 in the coil unit may be wound one turn, less than one turn, or multiple turns. In embodiments where the coil body 11 is wound one turn, the coil unit in the magnetic element may have only one turn; in embodiments where the coil body 11 is wound less than one turn, the magnetic element further includes a wire or coil connected in series with the coil unit to surround the magnetic core at least one turn, so that the coil unit and the wire or coil meet the basic magnetic field change requirements after being energized; in embodiments where the coil body 11 is wound multiple turns, the coil unit in the magnetic element may have a multi-turn structure.

[0071] In embodiments where the magnetic element includes a magnetic core and a coil winding, the coil winding may have one or more turns, the coil winding is wound on the magnetic core, and the coil winding can meet the requirements of conventional magnetic field changes after being energized.

[0072] Regardless of whether the magnetic element includes a coil winding or a single coil, the magnetic element can ensure the heat dissipation area of ​​the entire magnetic element through the heat dissipation channel 10 formed by the gap between two adjacent sheet coils 1 of the single coil, thereby increasing the heat transfer coefficient of the magnetic element and reducing the temperature rise; it can also reduce the contact resistance of the entire coil winding or single coil by using multiple sheet coils 1 arranged in parallel, while ensuring good contact of each connection section, thereby reducing the DC loss of the entire magnetic element; and in the high-frequency state, the multiple sheet coils 1 arranged in parallel can reduce the skin effect, thereby reducing the AC loss of the entire magnetic element.

[0073] Taking a transinductance regulator as an example, please refer to Figure 5. In the prior art, a transinductance regulator includes a housing core 21, a central core 22, an outer coil 23, and an inner coil 24. The outer coil 23 has a square coil structure, formed by bending a strip of copper wire with a cross-sectional area of ​​1.2 mm × 3 mm after tinning. The inner coil 24 also has a square coil structure, formed by bending a flat enameled wire with a cross-sectional area of ​​0.3 mm × 3 mm. The central core 22 serves as the core component of the inner coil 24 and is located within the space surrounding the inner coil 24. 24 and the middle core 22 serve as the core components of the outer coil 23, located within the space surrounding the outer coil 23. The outer coil 23, inner coil 24, and middle core 22 are all located within the outer shell core 21. Both the outer shell core 21 and the middle core 22 are insulated by spraying. The outer coil 23 and inner coil 24 are separated by an insulating layer, and both the inner and outer coils are spaced apart from the insulating layer. In this transinductance regulator, the outer coil 23 and inner coil 24 have little contact with the outside air, making it difficult for airflow to form inside.

[0074] The improved transinductance regulator structure according to this application is shown in Figure 6. The outer coil 23 is replaced by a coil unit, which includes six parallel-arranged sheet coils 1. Since the transinductance regulator is vertically soldered onto the PCB board, the hot air flows from the PCB board to the transinductance regulator in the direction of the arrangement of the PCB board and the transinductance regulator. Therefore, multiple sheet coils 1 in the coil unit are stacked in the direction of the winding axis of the coil body 11. A preset gap of 0.05 mm is left between two adjacent sheet coils 1. In this way, the hot air can pass through the gap between two adjacent sheet coils 1 in the coil unit, thus forming a heat dissipation channel 10 in the transinductance regulator. This can reduce the skin effect of the outer coil in the transinductance regulator and greatly reduce the temperature of the transinductance regulator.

[0075] Specifically, in the external coil 23 of the prior art transinductance regulator in Figure 5 and the coil unit serving as the external coil in the improved transinductance regulator in Figure 6, after passing 10A of AC current through them, the resistance values ​​of the two external coils are measured at different frequencies. Please refer to the tables below. Table 1 shows the resistance values ​​of the outer coil 23 of the prior art transinductance regulator in Figure 5 after 10A AC current is applied, measured at different frequencies. Table 2 shows the resistance values ​​of the outer coil in the improved transinductance regulator in Figure 6 after 10A AC current is applied, measured at different frequencies. From the data in the tables, it can be concluded that as the frequency increases, the difference between the resistance value of the outer coil in the improved transinductance regulator and the resistance value of the outer coil 23 in the prior art transinductance regulator becomes larger and larger. Furthermore, at high frequencies, the resistance value of the outer coil in the improved transinductance regulator is less than the resistance value of the outer coil 23 in the prior art transinductance regulator. Therefore, it can be concluded that the magnetic element of the coil unit protected by this application has a smaller resistance value, lower loss, and higher efficiency at high frequencies, which can meet the requirements of higher power applications.

[0076] Please refer to Figures 7 and 8. In Figure 5, the outer coil 23 of the prior art transinductance regulator and the coil unit serving as the outer coil in Figure 6 are respectively supplied with 50A DC current. Under the condition of an ambient temperature of 25℃, the temperature of the transinductance regulator is detected by infrared light. It is found that the lowest temperature value of the prior art transinductance regulator is 62.328℃ and the highest temperature value is 73.838℃, while the lowest temperature value of the improved transinductance regulator is 53.735℃ and the highest temperature value is 61.77℃. It can be concluded that the magnetic element of the coil unit protected by this application has a larger heat dissipation area and a lower temperature rise, which helps to reduce the aging failure rate of the magnetic element at high temperature and helps to extend the service life of the magnetic element.

[0077] The above examples illustrate the present invention only to aid in understanding it and are not intended to limit the scope of the invention. Those skilled in the art can make various simple deductions, modifications, or substitutions based on the principles of this invention.

Claims

1. A coil unit, characterized in that, The device includes multiple sheet coils formed by winding strip wire. Each sheet coil includes a coil body, a first connecting segment, and a second connecting segment. The first connecting segment and the second connecting segment are respectively connected to both ends of the coil body in the winding direction. The multiple sheet coils are stacked in the thickness direction of the strip wire. Adjacent sheet coils are spaced apart to form a heat dissipation channel. The first connecting segments of all sheet coils are connected, and the second connecting segments of all sheet coils are connected.

2. The coil unit as described in claim 1, characterized in that, The winding axis of the coil body is in the same direction as the thickness direction of the strip wire; or, the winding axis of the coil body is in the same direction as the width direction of the strip wire.

3. The coil unit as described in claim 1, characterized in that, The coil body has an open-loop structure, and the strip wire is wound around once to form the coil body.

4. The coil unit as described in claim 3, characterized in that, The winding axis of the coil body is in the same direction as the thickness direction of the strip wire, and the dimension of the coil body in the direction of the winding axis is equal to the thickness dimension of the strip wire; or, the winding axis of the coil body is in the same direction as the width direction of the strip wire, and the dimension of the coil body in the direction of the winding axis is equal to the width dimension of the strip wire.

5. The coil unit as described in claim 3, characterized in that, The first connecting segment and the second connecting segment are arranged at intervals in the winding direction of the coil body; The winding axis of the coil body is in the same direction as the thickness direction of the strip wire, and the size of the sheet coil in the direction of the winding axis is equal to the thickness of the strip wire; or, the winding axis of the coil body is in the same direction as the width direction of the strip wire, and the size of the sheet coil in the direction of the winding axis is equal to the width of the strip wire.

6. The coil unit as described in claim 1, characterized in that, The orientation of the first connecting segment is opposite to that of the second connecting segment; or, the orientation of the first connecting segment is the same as that of the second connecting segment, and the first connecting segment and the second connecting segment are arranged at intervals.

7. The coil unit as described in any one of claims 1 to 6, characterized in that, The first connecting segment has a first connecting end and a first suspension end located at both ends thereto, the first connecting end being connected to the coil body, and two adjacent first suspension ends being connected in the thickness direction of the strip wire; and / or, The second connecting segment has a second connecting end and a second suspension end located at both ends thereto. The second connecting end is connected to the coil body, and two adjacent second suspension ends are connected in the thickness direction of the strip wire.

8. The coil unit as described in any one of claims 1 to 6, characterized in that, In the thickness direction of the strip wire, two adjacent first connecting segments are connected by a solder layer, and / or two adjacent second connecting segments are connected by a solder layer.

9. The coil unit as described in any one of claims 1 to 6, characterized in that, The surface of the sheet coil is coated with an anti-oxidation layer.

10. The coil unit as described in any one of claims 1 to 6, characterized in that, The coil unit includes a support structure located between two adjacent coil bodies in the thickness direction of the strip wire, so that there is a predetermined gap between the two adjacent coil bodies to form the heat dissipation channel.

11. A coil winding, characterized in that, It includes multiple coil units as described in any one of claims 1 to 10, all of which have coaxial winding axes, and two adjacent coil units are arranged in the winding direction of the coil units and / or in the direction of the winding axis, and all of which are connected in series and / or in parallel.

12. A magnetic element, characterized in that, It includes a magnetic core, and also includes a coil unit as described in any one of claims 1 to 10 or a coil winding as described in claim 11.

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