Inductor, power converter, and uninterruptible power supply

Abstract

The present application provides an inductor, a power converter, and an uninterruptible power supply. The power converter comprises a first circuit board and a second circuit board; an inductor is provided on the first circuit board, and the first inductor comprises a first pin and a second pin; the first pin is electrically connected to the first circuit board; and the second pin is electrically connected to the second circuit board. The first circuit board and the second circuit board are electrically connected by means of the inductor, thereby reducing the number of cables and lowering the risk of arcing.

Description

An inductor, power converter and uninterruptible power supply

[0001] Cross-reference to related applications

[0002] This application claims priority to Chinese Patent Application No. 202411959109.8, filed on December 25, 2024, entitled “An Inductor, Power Converter and Uninterruptible Power Supply”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of power electronics, and more particularly to an inductor, a power converter, and an uninterruptible power supply. Background Technology

[0004] With the increasing demands for density and efficiency in power electronic devices, power electronic devices generally consist of multiple circuit boards. These circuit boards are mostly connected by terminals. The pins of the inductors fixed to the circuit boards need to be connected to the terminals of the circuit boards they belong to first, and then the terminals are connected to the terminals of other circuit boards. This results in too many circuit board terminals and low space utilization of power electronic devices. Summary of the Invention

[0005] This application provides an inductor, a power converter, and an uninterruptible power supply. The electrical connection between two circuit boards is achieved through the pins of the inductor, which can save the number of terminals and the space of the circuit board, and improve the energy density of the power converter.

[0006] In a first aspect, this application provides a power converter, which includes a first circuit board and a second circuit board. An inductor is disposed on the first circuit board, and the first inductor includes a first pin and a second pin. The first pin is electrically connected to the first circuit board, and the second pin is electrically connected to the second circuit board. By using the inductor pin as the medium for electrical connection between the first and second circuit boards, the connection between the inductor pin and the terminals of the first and second circuit boards is avoided. This not only saves on the number of terminals but also reduces the risk of insulation failure and arcing caused by exposed copper busbars due to excessive terminals.

[0007] In one possible implementation, the second circuit board of the first circuit board is arranged side by side along the first direction. The first pin and the second pin are respectively disposed on opposite sides of the inductor along the first direction. The length of the second pin is longer than that of the first pin, and the difference in length between the second pin and the first pin is [5, 20 mm]. Lengthening the second pin of the inductor facilitates the fixed connection between the second pin and the second circuit board, making the assembly between the inductor and the second circuit board simple and convenient.

[0008] In one possible implementation, the first circuit board and the second circuit board are positioned opposite each other along a second direction, with the first pin and the second pin respectively located on opposite sides of the inductor along the second direction. This design is suitable for scenarios where circuit boards are placed opposite each other, thus enriching the application scenarios of the inductor.

[0009] In one possible implementation, a first screw is provided on the first circuit board, and a first screw hole is provided on the first pin. The first pin is screwed into the first screw for connection. A second screw is provided on the second circuit board, and a second screw hole is provided on the second pin for connection. The second pin is screwed into the second screw for connection, thereby achieving an electrical connection between the first and second circuit boards. This screw-to-screw electrical connection method not only achieves an electrical connection between the inductor and the circuit board but also secures the inductor to the circuit board, preventing it from loosening and detaching from the circuit board during assembly.

[0010] In one possible implementation, insulating bosses are provided around the outer periphery of both the first and second pins, and the insulating bosses are fixedly connected to the base. On the one hand, the insulating bosses protect the first and second pins, preventing them from being exposed and causing arcing. On the other hand, the insulating bosses can position the pins, fixing them in place so that they do not deviate from the mounting holes on the circuit board.

[0011] In one possible implementation, the inductor includes a base, a magnetic core, and a coil. The magnetic core includes an upper yoke, a middle post, and a lower yoke. The upper and lower yokes are respectively disposed on both sides of the middle post. The coil is wound on the middle post to form a winding. The base has a hole, and at least a portion of the lower yoke is located within the hole and fixedly connected to the inner wall of the hole. The lower yoke is directly inserted into the base through the hole, and the lower yoke and the inner wall of the hole can be connected with adhesive to fix the magnetic core on the base.

[0012] In one possible implementation, the inductor includes a stud and a cover plate. The cover plate is positioned above the upper yoke. Both the cover plate and the base have protrusions. The projections of the protrusions on the cover plate and the base in their respective alignment directions at least partially overlap. The protrusions on the cover plate have a third screw hole, and the protrusions on the base have a fourth screw hole. The two ends of the stud are screwed into the third and fourth screw holes, respectively. The stud securely connects the base and the cover plate, enhancing the structural strength of the inductor.

[0013] In one possible implementation, insulating sheets are provided between the coil and the upper yoke, and between the coil and the upper yoke, to enhance the insulation performance between the coil and the upper and lower yokes, and to prevent arcing caused by insulation failure between the upper and lower yokes and the coil.

[0014] In one possible implementation, the inductor includes at least two magnetic cores arranged in parallel, with an insulating barrier between the two magnetic cores to ensure the insulation performance between the magnetic cores.

[0015] In one possible implementation, the coil has a rectangular cross-section with a length of [5mm, 8mm] and a width of [1.5mm, 3mm]. Using a flat coil increases the heat dissipation area and prevents the inductor from failing due to excessive heat.

[0016] In one possible implementation, the turn spacing between the coils is [0.6, 2.5 mm] to increase the heat dissipation area of ​​the coils.

[0017] Secondly, this application provides an uninterruptible power supply (UPS), which includes the aforementioned power converter for connecting to an AC power source. The power converter is used to convert the AC power output from the AC power source into power and then output it to the load.

[0018] Thirdly, this application provides an inductor, which includes a first pin and a second pin, which are used to electrically connect two circuit boards, and the two circuit boards are electrically connected through the inductor.

[0019] In one possible implementation, the first pin and the second pin are respectively disposed on opposite sides of the inductor, the inductor is fixed to one of the two circuit boards, the first pin is electrically connected to one of the circuit boards, and the second pin is electrically connected to the other of the two circuit boards.

[0020] In one possible implementation, the inductor includes a base, a magnetic core, and a coil. The magnetic core includes an upper yoke, a middle column, and a lower yoke. The upper and lower yokes are respectively disposed on both sides of the middle column. The coil is wound on the middle column to form a winding. The base has a hole, and at least a portion of the lower yoke is located inside the hole and is fixedly connected to the inner wall of the hole. Attached Figure Description

[0021] Figure 1 is a schematic diagram of the power converter provided in an embodiment of this application;

[0022] Figure 2 is a top view of an inductor provided in an embodiment of this application;

[0023] Figure 3 is a schematic diagram of the structure of an inductor provided in an embodiment of this application;

[0024] Figure 4 is a schematic diagram of another structure of an inductor provided in an embodiment of this application;

[0025] Figure 5 is an exploded view of the structure of an inductor provided in an embodiment of this application;

[0026] Figure 6 is a schematic diagram of another inductor structure provided in an embodiment of this application;

[0027] Figure 7 is an exploded view of the structure of another type of inductor provided in Figure 6.

[0028] Reference numerals: 100 - First circuit board; 200 - Second circuit board; 300 - Inductor; 310 - First pin; 311 - First screw hole; 320 - Second pin; 321 - Second screw hole; 330-cover plate; 340-base; 341-first boss; 342-second boss; 343-hole; 350-magnetic core; 351-upper yoke; 352-middle post; 353-lower yoke; 360-coil; 370-insulating sheet; 400-inductor; 410-first pin; 411-first screw hole; 420-second pin; 421-second screw hole; 430-cover plate; 431-first protrusion; 432-third screw hole; 440-base; 441-second protrusion; 442-fourth screw hole; 450-magnetic core; 451-upper yoke; 452-middle post; 453-lower yoke; 460-coil; 470-stud. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be further described in detail below with reference to the accompanying drawings. However, the exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein. The same reference numerals in the figures denote the same or similar structures, and therefore repeated descriptions of them will be omitted. The terms expressing position and direction described in the embodiments of this application are illustrative based on the accompanying drawings, but changes can be made as needed, and all such changes are included within the scope of protection of this application. The accompanying drawings of the embodiments of this application are only for illustrating relative positional relationships and do not represent actual scale.

[0030] With the increasing demand for high-power converters, power converters typically consist of multiple circuit boards. These circuit boards house various electronic components such as switching transistors, capacitors, and inductors, achieving different power conversion functions through different circuit topologies. Multiple circuit boards are electrically connected via terminals. Inductors are devices in power converters used to convert electrical energy into magnetic energy for storage. In practice, to achieve electrical connections between inductors and circuit boards, as well as between circuit boards and other circuit boards, the inductor's pins must first be electrically connected to the terminals of its own circuit board, which then connects to the terminals of other circuit boards. This connection method results in an excessive number of circuit board terminals, leading to low space utilization of the power converter. Furthermore, numerous terminals expose copper busbars, increasing the risk of arcing between them. Therefore, this application provides a power converter that utilizes the pins of an inductor to electrically connect two circuit boards, reducing the size of the two circuit boards, saving the number of terminals between circuit boards, and improving the space utilization of the power converter.

[0031] Referring to Figure 1, this embodiment of the application includes a power converter, which includes a first circuit board 100 and a second circuit board 200. An inductor 300 is disposed on the first circuit board 100. Both the first circuit board 100 and the second circuit board 200 can be printed circuit boards (PCBs). The inductor 300 includes a first pin 310 and a second pin 320. The first pin 310 is electrically connected to the first circuit board 100, and the second pin 320 is electrically connected to the second circuit board 200. In other words, this embodiment uses the pins of the inductor 300 as the medium for the electrical connection between the first circuit board 100 and the second circuit board 200, thereby avoiding the need for the pins of the inductor 300 to first connect to the terminals of the first circuit board 100 and then connect to the terminals of the second circuit board 200 through the terminals of the first circuit board 100, thus achieving the electrical connection between the first circuit board 100 and the second circuit board 200. This embodiment not only saves on the number of terminals but also reduces the risk of insulation failure and arcing caused by exposed copper busbars due to excessive terminals. The inductor 300 can be used in PFC circuits, inverter circuits, or other power topologies.

[0032] It should be noted that the first pin 310 and the second pin 320 can be reserved parts of the winding of the inductor 300 itself, or the external wires of the inductor 300 can be used as pins of the inductor 300.

[0033] Referring to the top view of inductor 300 shown in Figure 2 and the three-dimensional structural diagram of inductor 300 shown in Figure 3, the first pin 310 is provided with a first screw hole 311. Correspondingly, a screw is provided on the first circuit board 100. The first screw hole 311 of the first pin 310 engages with the screw on the first circuit board 100, thereby realizing the electrical connection between inductor 300 and the first circuit board 100, and simultaneously fixing inductor 300 to the first circuit board 100. The second pin 320 is provided with a second screw hole 321. Correspondingly, a screw can be provided on the second circuit board 200. The second screw hole 321 of the second pin 320 engages with the screw on the second circuit board 200, thereby realizing the electrical connection between the first circuit board 100 and the second circuit board 200. The screw-to-screw electrical connection method not only realizes the electrical connection between inductor 300 and the circuit board, but also fixes inductor 300 to the circuit board, preventing inductor 300 from loosening and falling off the circuit board during assembly.

[0034] It should be understood that, in order to further strengthen the fixation of the inductor 300 on the circuit board, the base 340 of the inductor 300 can be fixed to the corresponding circuit board by means of glue application or clips.

[0035] In practical applications, the first circuit board 100 and the second circuit board 200 can be arranged in various ways. For example, when the first circuit board 100 and the second circuit board 200 are arranged side by side along the first direction, the inductor 300 is located on the edge of the second circuit board 200 near the first circuit board 100. The first pin 310 and the second pin 320 can be located on opposite sides of the inductor 300 along the first direction. Since the second pin 320 needs to extend to the second circuit board 200 and be electrically connected to it, the length of the second pin 320 needs to be longer than that of the first pin 310. The difference in length between the second pin 320 and the first pin 310 is [5, 20 mm], leaving a margin for the connection between the second pin 320 and the second circuit board 200.

[0036] In another example, the first circuit board 100 and the second circuit board 200 can also be arranged opposite each other along the second direction. In this case, the first pin 310 and the second pin 320 can be located on opposite sides along the second direction. That is, the first pin 310 and the second pin 320 can be located on opposite sides along the height direction of the inductor 300, and then the first pin 310 and the second pin 320 can be fixed to the first circuit board 100 and the second circuit board 200 respectively, so that the first circuit board 100 and the second circuit board 200 are electrically connected through the inductor 300. In this case, the length between the first pin 310 and the second pin 320 is not limited.

[0037] Referring again to the structural diagram of inductor 300 shown in Figure 4, insulating bosses are provided around the outer periphery of both the first pin 310 and the second pin 320. These insulating bosses are fixedly connected to the base 340 of inductor 300. For example, a first boss 341 may be provided around the first pin 310, and a second boss 342 may be provided around the second pin 320. On one hand, the insulating bosses protect the first pin 310 and the second pin 320, preventing them from being exposed and causing arcing. On the other hand, the insulating bosses position the pins, fixing the first pin 310 and the second pin 320 so that they do not deviate from the mounting holes on the circuit board. The insulating boss can be a plastic boss, and the insulating boss can be integrally formed with the base 340 of the inductor 300. The bottom of the insulating boss can have an opening corresponding to the screw hole of the pin. The screw of the circuit board is screwed into the screw hole of the pin through the opening. The pin of the inductor 300 is located in the groove. The bottom of the groove can be fixed to the circuit board by adhesive, which enhances the fixation between the inductor 300 and the circuit board.

[0038] The length and width of the first boss 341 are both greater than the length and width of the first pin 310, and the length and width of the second boss 342 are both greater than the length and width of the second pin 320.

[0039] It is understandable that the first boss 341 and the second boss 342 can be integrally formed with the base 340. The integral forming process not only enhances the fixed connection between the first boss 341 and the second boss 342 and the base 340, but also simplifies the process and makes it easy to implement.

[0040] The base 340 can be made of plastic, as can the first boss 341 and the second boss 342. This design ensures the insulation performance of the base 340, the first boss 341 and the second boss 342 while reducing the weight of the base 340 and the bosses, thus achieving a lightweight design.

[0041] Referring to the exploded view of the inductor 300 shown in Figure 5, the inductor 300 includes a base 340, a magnetic core 350, a coil 360, and a cover plate 330. The magnetic core 350 includes an upper yoke 351, a central post 352, and a lower yoke 353. The upper yoke 351 and the lower yoke 353 are respectively disposed on both sides of the central post 352, and the coil 360 is wound on the central post 352 to form a winding. The base has a hole 343, and at least a portion of the lower yoke is located within the hole 343 and is fixedly connected to the inner wall of the hole. The cover plate 330 and the base 340 are fixedly connected by studs 470. That is, the lower yoke of the magnetic core 350 is directly recessed into the hole 343 of the base 340 and fixedly connected to the wall of the hole 343. The magnetic core 350 can be fixedly connected to the inner wall of the hole 343 by adhesive. Compared to the existing method of fixing the inductor 300 to the circuit board using a strip, directly fixing the magnetic core 350 to the base 340 enhances the connection strength of the magnetic core 350 to the base 340. The hole 343 can be a blind hole or a through hole. The cover plate 330 can be a layer of insulating paper wrapped around the outer surface of the upper yoke 351, or it can be an insulating plate placed above the upper yoke 351.

[0042] It should be noted that the current carrying method of coil 360 can be single-phase, two-phase or three-phase, and this application embodiment does not limit this.

[0043] In one example, insulating sheets 370 are provided between the coil 360 and the upper yoke 351, and between the coil 360 and the lower yoke 353. This replaces the existing method of using fiberglass tubing to insulate the coil 360 and the base 340, avoiding uneven distribution of the coil 360 due to the thicker fiberglass tubing. This effectively increases the minimum turn spacing of the winding, thereby improving the heat dissipation capacity of the winding. Similarly, an insulating sheet 370 is provided between the coil 360 and the cover plate 330 to enhance the insulation performance between the coil 360 and the cover plate 330, preventing arcing between the cover plate 330 and the coil 360 due to insulation failure.

[0044] In one example, the inductor 300 includes at least two magnetic cores 350 arranged side by side, with an insulating barrier between the at least two magnetic cores 350 to ensure insulation performance between the magnetic cores 350. The insulating barrier can be a plastic composite paper sheet, which can be integrally formed with the base 340 or separate from the base 340.

[0045] The cross-sectional shape of coil 360 is rectangular, with a length of [5mm, 8mm] and a width of [1.5mm, 3mm]. Inductor 300, as a component in the power converter that generates a significant amount of heat, utilizes a flat coil 360. This increases the heat dissipation area of ​​coil 360, preventing inductor 300 from failing due to excessive heat.

[0046] The turn spacing between coils 360 is [0.6, 2.5 mm]. Increasing the turn spacing between coils 360 increases the heat dissipation area of ​​coils 360. The turn spacing can be fixed by applying glue.

[0047] Figure 6 is a schematic diagram of another inductor 400 provided in an embodiment of this application, and Figure 7 is an exploded view of the inductor 400 shown in Figure 6. The inductor 400 includes a first pin 410 and a second pin 420. The first pin 410 has a first screw hole 411, which is electrically connected to a first screw on a first circuit board (not shown). The second pin 420 has a second screw hole 421, which is electrically connected to a second screw on a second circuit board (not shown). This avoids connecting the pins of the inductor 400 to the terminals of the first circuit board, and then connecting the pins of the first circuit board to the terminals of the second circuit board. This not only saves on the number of terminals but also reduces the risk of insulation failure and arcing caused by exposed copper busbars due to excessive terminals.

[0048] The inductor 400 includes a base 440, a magnetic core 450, and a coil 460. The magnetic core includes an upper yoke 451, a middle post 452, and a lower yoke 453. The upper yoke 451 and lower yoke 453 are respectively disposed on both sides of the middle post 452. The coil 460 is wound on the middle post 452 to form a winding. The base 440 has a hole (not shown in the figure), and at least a portion of the lower yoke 453 is located inside the hole and fixedly connected to the inner wall of the hole. Compared with the prior art method of fixing the inductor 400 to the circuit board by rolling strip, fixing the magnetic core 450 directly to the base 440 can enhance the firmness of fixing the magnetic core 450 to the circuit board. The hole can be a blind hole or a through hole. The magnetic core 450 can be placed horizontally or vertically relative to the base 440.

[0049] The inductor 400 also includes a stud 470 and a cover plate 430. The cover plate 430 is disposed above the upper yoke 451 and can also wrap around the outer periphery of the upper yoke 451. The cover plate 430 is made of an insulating material, such as plastic, to enhance the insulation between the cover plate 430 and the upper yoke 451. Both the cover plate 430 and the base 440 are provided with protrusions. The cover plate 430 is provided with a first protrusion 431, and the base 440 is provided with a second protrusion 441. The projections of the first protrusion 431 and the second protrusion 441 in the arrangement direction of the cover plate 430 and the protrusions at least partially overlap. The first protrusion 431 is provided with a third screw hole 432, and the second protrusion 441 is provided with a fourth screw hole 442. The two ends of the stud 470 are screwed into the third screw hole 432 and the fourth screw hole 442, respectively. This prevents the inductor 400 from falling off when it is inverted on the circuit board.

[0050] Based on the same inventive concept, this application also provides an uninterruptible power supply (UPS), which includes the aforementioned power converter. The power converter is used to connect to an AC power source and to convert the AC power output from the AC power source into power before outputting it to the load.

[0051] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A power converter, characterized by, The power converter comprises a first circuit board and a second circuit board, the first circuit board is provided with an inductor, the inductor comprises a first pin and a second pin, the first pin is electrically connected with the first circuit board, and the second pin is electrically connected with the second circuit board.

2. The power converter of claim 1, wherein, The first circuit board and the second circuit board are arranged side by side along a first direction, the first pin and the second pin are arranged on two sides of the inductor opposite to each other along the first direction, and the length of the second pin is longer than that of the first pin.

3. The power converter of claim 1, wherein, The first circuit board and the second circuit board are arranged opposite to each other along a second direction, the first pin and the second pin are arranged on two sides of the inductor opposite to each other along the second direction.

4. A power converter according to any one of claims 1-3, characterized in that, The first circuit board is provided with a first screw, the first pin is provided with a first screw hole, the first pin is screw-connected with the first screw, the second circuit board is provided with a second screw, the second pin is provided with a second screw hole, and the second pin is screw-connected with the second screw.

5. The power converter of claim 4, wherein, The first pin and the second pin are both annularly provided with an insulating boss, and the insulating boss is fixedly connected with a base of the inductor.

6. The power converter of any of claims 1-5, wherein, The inductor comprises a base, a magnetic core and a coil, the magnetic core comprises an upper yoke, a middle column and a lower yoke, the upper yoke and the lower yoke are arranged on two sides of the middle column respectively, the coil is wound on the middle column to form a winding, and the base is provided with a hole, at least part of the lower yoke is located in the hole and is fixedly connected with an inner wall of the hole.

7. The power converter of claim 6, wherein, The inductor comprises a stud and a cover plate, the cover plate is arranged above the upper yoke, the cover plate and the base are both provided with a protrusion, a projection of the protrusion of the cover plate on an arrangement direction of the cover plate and the base at least partially overlaps with a projection of the protrusion of the base, the protrusion of the cover plate is provided with a third screw hole, the protrusion of the base is provided with a fourth screw hole, and two ends of the stud are screw-connected with the third screw hole and the fourth screw hole respectively.

8. A power converter as claimed in claim 6 or 7, characterised in that, Insulating sheets are arranged between the coil and the upper yoke and between the coil and the lower yoke.

9. A power converter according to any of claims 6-8, characterized in that, The inductor comprises at least two magnetic cores arranged side by side, and at least two insulating barriers are arranged between the at least two magnetic cores.

10. A power converter according to any of claims 6-9, characterized in that, The cross-sectional shape of the coil is rectangular.

11. An uninterruptible power supply, characterized by The uninterruptible power supply comprises the power converter according to any one of claims 1-10, the power converter is used for connecting an alternating current power supply, and the power converter is used for performing power conversion on alternating current output by the alternating current power supply and outputting the alternating current to a load.

12. An inductor, characterized by The inductor comprises a first pin and a second pin, the first pin and the second pin are respectively used for electrically connecting two circuit boards, and the two circuit boards are electrically connected through the inductor.

13. The inductor of claim 12, wherein, The first pin and the second pin are arranged on two sides of the inductor opposite to each other, the inductor is fixed to one of the two circuit boards, the first pin is electrically connected with the one circuit board, and the second pin is electrically connected with the other circuit board of the two circuit boards. The first pin and the second pin are arranged on two sides of the inductor opposite to 14. The inductor of claim 12 or 13, wherein, The inductor comprises a base, a magnetic core and a coil, the magnetic core comprises an upper yoke, a middle column and a lower yoke, the upper yoke and the lower yoke are arranged on two sides of the middle column respectively, the coil is wound on the middle column to form a winding, and the base is provided with a hole, at least part of the lower yoke is located in the hole and is fixedly connected with the inner wall of the hole.

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