Toroidal Inductor Bracket with Insulating Pad
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Solution Overview
Problem
Existing bracket devices for high-power uninterruptible power supplies, particularly those using vertical winding toroidal inductors, face issues with heat dissipation, increased part complexity, and instability due to uneven copper bar spacings, leading to potential swaying or tilting of inductor components which can damage the inductor's stability.
Innovation Solution
A bracket device with an insulating pad having an integrally formed positioning structure that is embedded between adjacent wires of the coil, combined with a fastener that wraps around the toroidal magnetic core, provides stable fixation and isolation, reducing the number of components and allowing for effective heat dissipation without affecting the positioning structure's stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is attached to the outer circumference of the coil to isolate the steel strip from the coil, then the electrical insulation is improved, but the heat dissipation of the inductor deteriorates
Solution Approach 1:
The patent introduces an insulating pad as an intermediary component between the bracket and the coil, rather than attaching insulation directly to the coil. This insulating pad serves as a mediator that provides electrical insulation while being thermally conductive or at least not interfering with the coil's heat dissipation path, thus resolving the contradiction between insulation and heat dissipation
Solution Approach 2:
The patent extracts the insulation function from the coil structure itself and places it in a separate insulating pad component. This separation allows the coil to maintain its original heat dissipation characteristics while the insulating pad provides the necessary electrical isolation, preventing the insulation from becoming a thermal barrier on the coil surface
2Stability of the object's composition
If multiple independent positioning blocks and additional fasteners are added to limit inductor movement, then the fixation stability is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions (positioning, clamping, and fixation) into a single integrated bracket structure with specifically designed geometric features. The bracket includes positioning blocks and clamping structures that work together as one unified component, eliminating the need for multiple separate positioning blocks and additional fasteners, thus reducing device complexity while maintaining fixation stability
Solution Approach 2:
The bracket is designed as a multi-functional component that simultaneously provides structural support, electrical insulation, inductor positioning, and movement restriction. This universal design allows a single component to perform multiple functions that would otherwise require separate parts, thereby simplifying the overall device structure while ensuring stable inductor fixation
3Ease of manufacture
If the positioning block shape does not adapt to unequal spacings between copper bars, then the manufacturing simplicity is maintained, but the inductor stability deteriorates due to copper bar swaying or tilting
Solution Approach 1:
The patent employs asymmetric positioning block designs that are specifically shaped to match the unequal spacings between copper bars at different locations of the coil. The positioning blocks have varying dimensions and geometries tailored to the specific spacing requirements at different axial positions, allowing them to fit precisely without causing copper bar swaying or tilting, thus maintaining inductor stability while remaining manufacturable
Solution Approach 2:
The positioning blocks are designed with locally optimized geometries that adapt to the specific spacing conditions at different locations along the coil. Each positioning block has tailored dimensions and shapes that match the local spacing requirements, providing precise fit and support without affecting adjacent copper bars, thereby maintaining overall inductor stability
Data Source
AI summary
The present invention relates to a bracket device for bearing an inductor, an inductor device, and an uninterruptible power supply. The inductor comprises a toroidal magnetic core; and a coil comprising a plurality of wires wound around the toroidal magnetic core. The bracket device comprises: a bracket having a bearing portion adapted to bear the inductor; an insulating pad adapted to be sandwiched between the inductor and the bearing portion of the bracket, the insulating pad having an integrally formed positioning structure capable of being embedded between two adjacent wires of the coil and keeping the toroidal magnetic core fixed; and a fastener adapted to wrap around the toroidal magnetic core and press the toroidal magnetic core together with the insulating pad against the bracket. The bracket device of the present invention is capable of effectively fixing an inductor and allowing it to dissipate heat well.