CN115621010A - A high power inductor - Google Patents

Abstract

The present application discloses a high-power inductor. The high-power inductor includes a magnetic core assembly in a closed loop and a conductor assembly passing through the closed loop space of the magnetic core assembly. The conductor assembly includes a first conductor with two ends and a The second conductor has two ends, one end of the first conductor is bent back from the outside of the magnetic core assembly and the corresponding end of the second conductor is connected to each other as a whole. One end of the first conductor is turned back and bent from the outside of the magnetic core assembly and the corresponding end of the second conductor is connected to each other to form a whole-body linear conductor assembly, which realizes the winding effect of the conductor assembly in a limited space. The inductance of the geometric progression is multiplied, which improves the problem of unsatisfactory magnetic ring inductance and saves space and cost.

Description

A high power inductor

technical field

The application relates to the field of electrical components, in particular to a high-power inductor.

Background technique

Inductors are able to convert electrical energy into magnetic energy and store them, and consist of magnetic cores and windings. The inductance of the ring inductor depends on the inductance of the core and the number of turns of the winding, according to the following calculation formula:

L=AL*N², where:

L——The inductance of the ring inductance

AL - the inductance of the magnetic core

N - the number of turns of the winding

It can be seen from the above formula that the inductance of the magnetic core remains unchanged, and the inductance of the inductance is proportional to the square of the number of turns of the winding.

As shown in Figure 1, a toroidal inductor includes a toroidal core and a winding wound around the toroidal core. In order to be able to pass a large amount of current, the windings of high-power inductors often have large wire diameters, but the carrying capacity of multi-strand flexible wires is limited, so the bus bars of high-power inductors are usually copper bars with rectangular cross-sections. As shown in Figure 2, in the prior art, high-power inductors often directly pass through the toroidal magnetic core through copper bars, and the inductance of this direct-through inductance is only the inductance of a magnetic ring, which is far below the Ideal sense of volume.

Copper bars are generally relatively hard, and it is difficult to wind arbitrarily on the magnetic ring to form a multi-turn structure like multi-strand flexible wires. However, the carrying capacity of the flexible wire is limited. If you want to pass a large amount of current, you need to increase the diameter of the flexible wire. However, when the diameter of the flexible wire is increased, the hardness of the flexible wire will also increase accordingly, and it is also difficult to wind a wire with a higher hardness on the magnetic core. At present, as the demand for inductors in high-current scenarios continues to increase, copper bars are the preferred solution for conductors of high-power inductors because they can pass large-flow currents. However, the multi-turn structure of copper bars is difficult to achieve, making high-power inductors The amount of feeling is not up to the ideal amount.

Contents of the invention

In order to realize multi-turn winding of a conductor of a high-power inductor, the present application provides a high-power inductor.

A high-power inductor provided by this application adopts the following technical solution:

A high-power inductor, comprising a magnetic core assembly in a closed loop and a conductor assembly passing through the closed loop space of the magnetic core assembly, the conductor assembly includes a first conductor with two ends and a second conductor with two ends Two conductors, one end of the first conductor is bent back from the outside of the magnetic core assembly and the corresponding end of the second conductor is connected to each other as a whole.

By adopting the above-mentioned technical solution, the conductor assembly as a winding is composed of a first conductor and a second conductor. After passing through the closed loop space of the magnetic core assembly, the first conductor and the second conductor pass through one end of the first conductor from the magnetic The outer side of the core component is turned back and bent and the corresponding end of the second conductor is connected to each other to form a whole-body linear conductor component to realize the winding effect of the conductor component in a limited space, so that the geometric series of inductance is multiplied by the winding, improving The problem of unsatisfactory magnetic ring inductance is solved, and space and cost are saved.

Optionally, one end of the second conductor used to connect to the first conductor extends radially of the magnetic core assembly and turns around to avoid the first conductor located inside the magnetic core assembly. One end reaches one end of the first conductor outside the magnetic core assembly to be connected to the corresponding end of the first conductor, and the first conductor is connected to the second conductor to form a layer of winding.

By adopting the above technical scheme, because the conductor assembly of the high-power inductor has a large wire diameter and the space of the closed loop space of the magnetic core assembly is limited, when the first conductor and the second conductor pass through the closed loop space of the magnetic core assembly , may be partially or completely overlapped. Therefore, when one end of the first conductor is bent back from the outside of the magnetic core assembly and connected to the corresponding end of the second conductor, the second conductor will be interfered by the first conductor. In the above technical solution, the second conductor extends along the radial direction of the magnetic core assembly and revolves to avoid the interference of the first conductor, so as to realize the connection with the first conductor, and then realize the winding of the conductor assembly in a limited space. The turn effect improves the problem of unsatisfactory magnetic ring inductance, saving space and cost.

Optionally, the magnetic core assembly is in the shape of a circular or elliptical ring, a racetrack ring or a square tube.

By adopting the above technical solution, the circular, elliptical annular, racetrack annular and square tubular magnetic cores are all formed with a ring wall for the conductor assembly to wind.

Optionally, the first conductor and the second conductor are conductors with a rectangular cross section.

By adopting the above technical solution, the flow of current that can pass through the first conductor and the second conductor is increased.

Optionally, both the first conductor and the second conductor are surface-bending turns perpendicular to the thickness direction, wherein the thickness direction is the shortest of the first conductor and the second conductor (22). The length direction of the edge.

By adopting the above technical scheme, when the conductor with a rectangular cross section is wound, the surface perpendicular to the thickness direction is bent and wound, so that in a limited space, the specification of the conductor assembly that can be wound is improved as much as possible. To increase the flow of current that can pass through the first conductor and the second conductor.

Optionally, the surface perpendicular to the thickness direction of the first conductor is connected to the surface perpendicular to the thickness direction of the second conductor, wherein the surface perpendicular to the thickness direction is perpendicular to the first conductor, the The face of the shortest side of the second conductor.

By adopting the above technical solution, the flow path of the current flowing from the first conductor to the second conductor is increased, so as to realize a larger flow of current flow.

Optionally, the magnetic core assembly is provided with a plurality of the conductor assemblies, and the plurality of the conductor assemblies are serially connected in series to form a winding structure of more than two turns.

By adopting the above technical solution, in addition to the first conductor and the second conductor, a greater number of conductors of the magnetic core assembly provided with the same connection feature are connected to each other to form a winding structure of more than two turns. The conductor assembly forms a multi-turn winding, which improves the inductance of the high-power inductor.

Optionally, the magnetic core assembly is symmetrically provided with the conductor assembly.

By adopting the above technical solution, a common mode inductor is formed.

In summary, the present application includes at least one of the following beneficial technical effects:

1. One end of the first conductor is turned back and bent from the outside of the magnetic core assembly and the corresponding end of the second conductor is connected to each other to form a whole-body linear conductor assembly to realize the winding effect of the conductor assembly in a limited space. It brings geometric progression of inductance multiplication, improves the problem of unsatisfactory magnetic ring inductance, and saves space and cost.

2. The second conductor extends along the radial direction of the magnetic core assembly and turns around to avoid the interference of the first conductor, so as to realize the connection with the first conductor.

Description of drawings

FIG. 1 is a schematic structural diagram of a ring inductor in the prior art.

Fig. 2 is a schematic structural diagram of a high-power inductor in the prior art.

Fig. 3 is a schematic structural diagram of a high-power inductor.

Fig. 4 is a schematic structural diagram of a conductor assembly.

Fig. 5 is a schematic diagram of the structure of the second conductor.

Explanation of reference numerals: 1. Magnetic core component; 2. Conductor component; 21. First conductor; 22. Second conductor; 23. U-shaped connection end; 24. First pin; 25. Second pin.

detailed description

The application will be described in further detail below in conjunction with the accompanying drawings.

The embodiment of the present application discloses a high-power inductor. Referring to Figure 3, the high-power inductor includes a magnetic core assembly 1 and a conductor assembly 2, the magnetic core assembly 1 is annular, the conductor assembly 2 is used to conduct current, and the conductor assembly 2 is bent and wound to the ring wall of the magnetic core assembly 1 superior.

In different embodiments, the magnetic core assembly 1 can include different numbers of annular magnetic cores, and the number of annular magnetic cores can be set according to the inductance of the required high-power inductance. One annular magnetic core can also be set, and multiple If a plurality of annular magnetic cores are provided, the plurality of annular magnetic cores can be arranged coaxially (not shown in the figure). In different embodiments, the magnetic core can be in different annular shapes, as long as a ring wall for the conductor assembly 2 can be formed, the magnetic core can be circular, elliptical, or racetrack-shaped. or square tube.

The conductor assembly 2 is used to conduct current. In different embodiments, the conductor assembly 2 can be made of different materials, as long as it has excellent electrical conductivity, as an example, the conductor assembly 2 can be made of copper, and copper is used to make the conductor assembly 2 because copper metal It has excellent electrical conductivity and is easy to process into a rectangular plate-shaped conductor.

3 and 4, in different embodiments, the conductor assembly 2 can be wound on the ring wall of the magnetic core assembly 1 in different ways, as an example, the conductor assembly 2 includes a first conductor 21 with two ends and the second conductor 22 having two ends, the first conductor 21 and the second conductor 22 are both passed through the closed loop space of the magnetic core assembly 1 . One end of the first conductor 21 is bent back from the outside of the magnetic core assembly 1 to form a U-shaped conductor, and the second conductor 22 is connected to one end of the first conductor 21 outside the magnetic core assembly 1 . Specifically, one end of the first conductor 21 located inside the magnetic core assembly 1 extends along the axial direction of the magnetic core assembly 1 toward a direction away from the magnetic core assembly 1 , and a first pin 24 of an inductor is formed on the extended portion. So set, the current can flow into the first conductor 21 through the first pin 24, and after penetrating into the closed loop of the magnetic core assembly 1, then flow out of the closed loop of the magnetic core assembly 1 along the first conductor 21, and then pass through the closed loop of the magnetic core assembly 1. The second conductor 22 flows into the closed loop of the magnetic core assembly 1 , and finally passes through the closed loop of the magnetic core assembly 1 through the second conductor 22 to complete the current winding.

With reference to Fig. 3 and Fig. 5, the second conductor 22 is connected with the first conductor 21, and in different embodiments, the end that the second conductor 22 is used for being connected with the first conductor 21 can be different shapes, as long as can be with the first The conductors 21 are connected and can avoid the interference of the first conductor 21. As an example, one end of the second conductor 22 used to connect to the second conductor 22 extends along the radial direction of the magnetic core assembly 1 and then bends to form a The U-shaped connecting end 23 , one end of the first conductor 21 located inside the magnetic core assembly 1 passes through the gap of the U-shaped connecting end 23 . In this way, the second conductor 22 avoids the interference of the first conductor 21 and realizes the connection with the first conductor 21, thereby realizing the winding of the conductor assembly 2 in a limited space and improving the magnetic loop inductance. Ideal problem, saving space cost. Referring to FIG. 1 , specifically, the end of the second conductor 22 away from the U-shaped connection end 23 extends along the axial direction of the magnetic core assembly 1 toward a direction away from the magnetic core assembly 1 , and an inductor second pin 25 is formed on the extension.

It should be noted that the above-mentioned first conductor 21 and second conductor 22 are all pre-processed into a curved shape before assembly, the shape of the first conductor 21 matches the shape of the second conductor 22, and the size of the first conductor 21 Cooperate with the size of the second conductor 22 to ensure that the two do not interfere with each other after winding, and do not interfere with the magnetic core assembly 1 . After combination, the corresponding ends of the two can be directly combined without on-site processing of their shapes, and at the same time, the high-power inductor can be easily realized in large-scale production. Both the first conductor 21 and the second conductor 22 are pre-processed before assembly to ensure precise structural dimensions and low processing costs. In the following description, it should also be considered by default that the shape and size of the first conductor 21 and the shape and size of the second conductor 22 have been pre-designed and calculated and pre-processed.

Referring to Fig. 3 and Fig. 4, in order to improve the specifications of the conductor assembly 2 that can be wound as much as possible in a limited space, so as to increase the current that can pass through the inductance, a specific but non-limiting structure is proposed, the magnetic core The component 1 is in the shape of an oval ring, the cross sections of the first conductor 21 and the second conductor 22 are both rectangular, the first conductor 21 and the second conductor 22 are bent perpendicular to the thickness direction, and the second conductor 22 is opposite It is arranged on the part of the first conductor 21 located inside the magnetic core assembly 1 . In a limited space, increasing the thickness and width of the first conductor 21 and the thickness and width of the second conductor 22 as much as possible can increase the flow path of the current, thereby improving the flow rate of the first conductor 21 and the second conductor 22. flux of current. Specifically, in order to increase the current flow path from the first conductor 21 to the second conductor 22, the surface perpendicular to the thickness direction of the end of the second conductor 22 used to connect to the first conductor 21 is perpendicular to the first conductor 21 The surface lamination in the thickness direction increases the contact area between the first conductor 21 and the second conductor 22 , thereby increasing the current flow from the first conductor 21 to the second conductor 22 .

In order to improve the inductance of high-power inductance, the magnetic core assembly 1 can be provided with a plurality of conductor assemblies 2, and the plurality of conductor assemblies 2 are connected in series (not shown in the figure), that is, the first conductor 21 and the second conductor In addition to 22, the magnetic core assembly 1 adopts a larger number of conductors with the same connection feature to be connected to each other, forming a winding structure with more than two turns. The quantity of the conductor assembly 2 is set according to the inductance of the required high-power inductance. Specifically, two winding structures formed by the conductor assembly 2 may be provided, and the two winding structures are mirrored on two opposite parts of the magnetic core assembly 1 to form a common mode inductance.

All of the above are preferred embodiments of the application, and are not intended to limit the protection scope of the application. Therefore, all equivalent changes made according to the structure, shape, and principle of the application should be covered by the protection scope of the application. Inside.

Claims (8)

1. The high-power inductor comprises a magnetic core assembly (1) in a closed loop and a conductor assembly (2) penetrating through a closed loop space of the magnetic core assembly (1), and is characterized in that the conductor assembly (2) comprises a first conductor (21) with two ends and a second conductor (22) with two ends, wherein one end of the first conductor (21) is bent back from the outer side of the magnetic core assembly (1) and is connected with the corresponding end of the second conductor (22) into a whole.

2. A high power inductor according to claim 1, wherein the end of the second conductor (22) connected to the first conductor (21) extends along the radial direction of the magnetic core assembly (1) and winds around and avoids the end of the first conductor (21) located inside the magnetic core assembly (1) to reach the end of the first conductor (21) located outside the magnetic core assembly (1) for connecting to the corresponding end of the first conductor (21), and the first conductor (21) and the second conductor (22) form a layer of winding after being connected.

3. A high power inductor according to claim 1 or 2, characterized in that said core assembly (1) is in the shape of an elliptical ring or race-track ring or square tube or circle.

4. A high power inductor according to claim 2, characterized in that said first conductor (21) and said second conductor (22) are rectangular conductors in cross-section.

5. A high power inductor according to claim 4, wherein the first conductor (21) and the second conductor (22) are each a surface-bent turn perpendicular to the thickness direction, wherein the thickness direction is the length direction of the shortest side of the first conductor (21) and the second conductor (22).

6. A high power inductor according to claim 4, wherein the surface perpendicular to the thickness direction of the first conductor (21) is connected to the surface perpendicular to the thickness direction of the second conductor (22), and the surface perpendicular to the thickness direction is the surface perpendicular to the shortest side of the first conductor (21) and the second conductor (22).

7. A high power inductor according to claim 1 or 2 or 4 or 5 or 6, characterized in that a plurality of said conductor assemblies (2) are arranged on said magnetic core assembly (1), and a plurality of said conductor assemblies (2) are connected in series in turn and form a turn structure with more than two turns.

8. A high power inductor according to claim 7, characterized in that said magnetic core assembly (1) is symmetrically arranged with said conductor assembly (2).

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