Integrated Inductor Assembly With Silicon-Iron Core and Cooling
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Solution Overview
Problem
The installation of boost inductors is complex and inefficient due to the need for multiple assembly steps and the use of amorphous magnetic cores, which result in high core loss and inefficiency in energy transfer processes.
Innovation Solution
An inductor assembly with an integrated housing and module design, featuring a silicon-iron alloy magnetic core and a conductive plate for improved electrical connections, along with a cooling channel for heat dissipation, allowing for direct installation and reduced assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate assembly installation method is used, then installation flexibility is maintained, but installation process becomes complex and efficiency decreases
Solution Approach 1:
The patent combines the inductor module, housing, and connecting member into an integrated assembly where the connecting member is pre-installed on the housing and the inductor module is fixed inside the housing. This merging of components into a pre-assembled unit eliminates the need for separate installation steps, thereby improving installation efficiency while reducing process complexity.
2Loss of energy
If amorphous magnetic core is used, then inductor functionality is achieved, but core loss increases and energy transfer efficiency decreases
Solution Approach 1:
The patent changes the material parameter of the magnetic core from amorphous material to silicon-iron alloy. This material substitution reduces magnetic core loss and improves energy transfer efficiency while maintaining the necessary inductor functionality. The silicon-iron alloy provides better magnetic properties with lower hysteresis loss compared to amorphous cores.
3Loss of time
If multiple separate components are used, then component functionality is maintained, but assembly steps increase and installation time increases
Solution Approach 1:
The patent implements preliminary assembly by pre-installing the connecting member on the housing and fixing the inductor module inside the housing before final installation. The wiring hole is also pre-formed in the housing for wiring harness passage. These preliminary actions reduce the number of steps required during final installation, thereby reducing installation time and simplifying the assembly process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the installation process, reduces magnetic core loss, and enhances the efficiency of energy transfer by using a silicon-iron alloy magnetic core and conductive plates for improved electrical connections and heat dissipation, leading to a more efficient and reliable inductor assembly.
Implementation Method 1
at least one wall of the housing has a cooling channel
Implementation Method 2
cooling channel for heat dissipation
Implementation Method 3
The inductor module is fixedly installed in the housing, and includes a magnetic core and a coil
Implementation Method 4
the material of the magnetic core is silicon-iron alloy
Data Source
AI summary
Provided are an inductor assembly and an inductor device. The inductor assembly includes an inductor housing and an inductor module. The inductor housing includes a housing and a connecting member which are integrally formed. The housing is a sealed structure, and the connecting member is located outside the housing. The housing is hollow, and is provided with a wiring hole. The connecting member is configured to connect to an object to be installed. The inductor module is fixedly installed in the housing, and the inductor module includes a magnetic core and a coil.