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WO2020119589A1 - 电子设备与其滤波电感器 - Google Patents

电子设备与其滤波电感器 Download PDF

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Publication number
WO2020119589A1
WO2020119589A1 PCT/CN2019/123503 CN2019123503W WO2020119589A1 WO 2020119589 A1 WO2020119589 A1 WO 2020119589A1 CN 2019123503 W CN2019123503 W CN 2019123503W WO 2020119589 A1 WO2020119589 A1 WO 2020119589A1
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WIPO (PCT)
Prior art keywords
filter inductor
magnetic
magnetic core
frequency range
rib
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PCT/CN2019/123503
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English (en)
French (fr)
Inventor
沈唐兵
李双佳
单亮
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西门子电动汽车动力总成系统(上海)有限公司
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Publication of WO2020119589A1 publication Critical patent/WO2020119589A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets

Definitions

  • the present invention relates to an electronic device, and in particular to a filter inductor of an electronic device.
  • a high-power power system usually includes a high-power power module, such as a converter module or an inverter module.
  • a high-power power module such as a converter module or an inverter module.
  • This type of power module is usually unable to meet the International Special Committee on Radio Interference (CISPR, originally known as Comotti International Spearcial Perturbations Radioélectriques) in the full frequency range or at least some frequency ranges.
  • CISPR International Special Committee on Radio Interference
  • CISPR Comotti International Spearcial Perturbations Radioélectriques
  • Regulatory standards and other standards especially in the frequency range and/or a high-frequency range required by the drive system of an electric vehicle (EV) or hybrid electric vehicle (HEV).
  • EV electric vehicle
  • HEV hybrid electric vehicle
  • CM common-mode
  • CM differential mode
  • DM Differential-mode
  • FIG. 1 is a schematic diagram of all aspects of a filter inductor 100 in the prior art.
  • the filter inductor 100 is disposed at the input end of a high-power power module in a high-power power system.
  • the filter inductor 100 includes a housing 41, a magnetic core 26, two positive and negative busbars 11, a central column 202, a side column 201, a central gap 65, and at least one side gap.
  • the two bus bars 11 are embedded in the magnetic core 26 and divide the magnetic core 26 into a central post 202 and a side post 201.
  • the center post 202 is located between the two bus bars 11, and the rest of the magnetic core 26 is the side post 201.
  • the central air gap 45 and the at least one side air gap are located in the center post 202 and the side post 201, respectively, so that the one shown in FIG. 1 is formed, and the cut surface of the filter inductor 100 seems to be an H-shaped structure .
  • the magnetic core 26 is composed of a plurality of independent magnetic blocks 26a, 26b.
  • the assembly method is to use an adhesive layer 33 to bond the magnetic blocks 26a, 26b together.
  • the material of the adhesive layer 33 may be a single-liquid type epoxy resin adhesive (EPORITE 2089).
  • the housing 41 is used to accommodate the magnetic core 26 and the bus bar 11. Therefore, the design of the volume and shape of the housing 41 must match the respective volume and shape of the magnetic core 26 and the two bus bars 11.
  • the housing 41 may be composed of multiple housing components, such as an upper half housing 41a and a lower half housing 41b in this embodiment.
  • the material of the magnetic core 26 is a magnetic material, which can be selected from one of the following soft magnetic materials: ferrite, amorphous soft magnetic material, and iron powder. If the material of the magnetic core 26 is MnZn ferrite, because of its high magnetic permeability, it is only suitable for a low frequency range (for example, between 1K and 30M Hz), the filter inductor 100 can only Used to attenuate common mode and differential mode noise in this low frequency range.
  • NiZn ferrite is used as the material of the magnetic core 26, due to its high impedance in a high frequency range (eg, between 30M and 1000M Hz), the filter inductance The device 100 can only be used to attenuate common-mode and differential-mode noise in this high-frequency range and eliminate electromagnetic interference.
  • the purpose of the present invention is to solve the above technical problem, and to provide a filter inductor with multiple magnetic cores for eliminating noise and electromagnetic interference in a full frequency range.
  • the present invention adopts the following technical solutions:
  • a filter inductor can be installed at an input end of an electronic device power module;
  • the filter inductor includes a plurality of magnetic cores and at least one conductor, the plurality of magnetic cores includes a first magnetic core and a first Two magnetic cores, wherein the at least one conductor is embedded in the first magnetic core;
  • the second magnetic core has a hollow portion for accommodating the first magnetic core, wherein the first magnetic core is composed of a first magnetic material , And the second magnetic core is composed of a second magnetic material, the second magnetic material is different from the first magnetic material.
  • both the first magnetic material and the second magnetic material can be selected from the following soft magnetic materials: ferrite, amorphous soft magnetic material, and iron powder.
  • the first magnetic material can eliminate noise and electromagnetic interference in a first frequency range
  • the second magnetic material can eliminate noise and electromagnetic interference in a second frequency range, the second frequency range is different from the The first frequency range.
  • the union of the first frequency range and the second frequency range covers a full frequency range, and the full frequency range is between 1K Hz and 1000M Hz.
  • one of the first magnetic material and the second magnetic material is nickel-zinc ferrite, and the other is manganese-zinc ferrite.
  • the filter inductor further includes a housing for accommodating the plurality of magnetic cores.
  • the filter inductor further includes a first fastening device, and the first fastening device is used to fix at least one magnetic core of the plurality of magnetic cores.
  • the first fastening device includes at least one first rib, and at least one first groove opposite to the at least one first rib, wherein the at least one first rib is disposed on at least one inner wall of the housing, and The at least one first groove provided on the surface of the second magnetic core corresponds to; or the at least one first groove is provided on at least one inner wall of the housing and is in contact with the at least one first groove provided on the surface of the second magnetic core A first rib corresponds.
  • the filter inductor further includes at least one conductor channel, the at least one conductor channel is formed inside the first magnetic core for passing the at least one conductor.
  • the filter inductor further includes a second fastening device, and the second fastening device is used to fix at least one of the plurality of magnetic cores.
  • the second fastening device includes at least one second rib, and at least one second groove opposite to the at least one second rib, wherein the at least one second rib is disposed on at least one outer wall of the at least one conductor channel And correspond to the at least one second groove provided on the surface of the portion where the first magnetic core contacts the at least one conductor channel; or at least one outer wall of the at least one conductor channel disposed in the at least one second groove And correspond to the at least one second rib provided on the surface of the portion where the first magnetic core is in contact with the at least one conductor channel.
  • At least one of the first magnetic core and the second magnetic core is composed of a plurality of independent magnetic blocks, and the composition method is to use an adhesive layer to adhere the plurality of magnetic blocks to together.
  • the filter inductor includes two conductors, the two conductors include two positive and negative bus bars, and the at least one conductor channel includes two conductor channels.
  • the first magnetic core includes a central post and a side post, and the central post is located between the two conductor channels.
  • the filter inductor includes at least one central gap, and the at least one central gap is located in the central column.
  • the invention also relates to an electronic device, including the above-mentioned filter inductor.
  • the electronic device is an inverter.
  • FIG. 1 is a schematic diagram of all aspects of a filter inductor 100 in the prior art.
  • 2a, 2b and 2c are each a schematic cross-sectional view of a first embodiment of a filter inductor 200 of the present invention.
  • 3a and 3b are each a schematic cross-sectional view of a second embodiment of the filter inductor 200 of the present invention.
  • 4a and 4b are each a schematic cross-sectional view of a third embodiment of the filter inductor 200 of the present invention.
  • 5a and 5b are each a schematic cross-sectional view of a fourth embodiment of the filter inductor 200 of the present invention.
  • FIGS. 2a, 2b and 2c are each a schematic cross-sectional view of a first embodiment of a filter inductor 200 of the present invention.
  • the filter inductor 200 is disposed in an electronic device, such as an input terminal of a high-power power module of a high-power power system, and has a plurality of magnetic cores to eliminate noise and electromagnetic interference in a full frequency range. At least two of the plurality of magnetic cores are made of magnetic materials different from each other.
  • the electronic device is an inverter.
  • the plurality of magnetic cores of the filter inductor 200 includes a first magnetic core 22 and a second magnetic core 55, and the second magnetic core 55 has a hollow portion, which is used to accommodate the first Magnetic core 22.
  • the filter inductor 200 has three magnetic cores, and includes a first magnetic core, a second magnetic core, and an outermost third magnetic core from the inside to the outside. Both the second magnetic core and the third magnetic core have a hollow portion for accommodating the first magnetic core and the second magnetic core, respectively.
  • the present invention is not limited to the number of the plurality of magnetic cores.
  • the filter inductor 200 further includes a housing 44 (as shown in FIG. 2c), at least one conductor channel 101, at least one conductor, a central post 202, at least one central gap 65, one side post 201 and at least one side Void.
  • the at least one conductor channel 101 is formed (also can be said to be embedded) inside the first magnetic core 22 for passing the at least one conductor.
  • the at least one conductor includes two bus bars that are positive and negative, and the two conductor channels 101 of the filter inductor 200 are used to pass the two bus bars.
  • the housing 44 its material may be a plastic.
  • the housing 44 is used to accommodate the plurality of magnetic cores (such as the first magnetic core 22 and the second magnetic core 55 in this embodiment), and is provided with the at least one conductor channel 101.
  • the design of the volume and shape of the housing 44 must match the volume and shape of the plurality of magnetic cores and the at least one conductor channel 101.
  • the structure of the housing 44 may be the housing 41 of the filter inductor 100 of FIG. 1, which may be composed of multiple housing parts, such as the upper half housing 41 a and the lower half housing 41 b; however, the present invention It is not limited to the implementation of the housing 44 (such as material, structure, size and shape, etc.).
  • the two conductor channels 101 of the filter inductor 200 divide the first magnetic core 22 into a central column 202 and a side column 201.
  • the center column 202 is located between the two conductor channels 101, and the remaining part is the side column 201.
  • the at least one central gap 65 and the at least one side gap are respectively located in the center pillar 202 and the side pillar 201, and are usually located in the middle of the center pillar 202 and the side pillar 201, respectively, thus forming a shape as shown in FIG. 2a
  • One, viewed from the section of the filter inductor 200, is an approximately H-shaped structure.
  • the at least one central gap 65 can be used to accommodate another component of the filter inductor 200, such as a sensor.
  • the filter inductor 200 has a plurality of central voids 65 located in the central pillar 202. Further, in other embodiments (not shown), the filter inductor 200 does not have the above-mentioned side gaps or has multiple side gaps. This embodiment is not limited to the number of the at least one central gap 65 and the at least one side gap.
  • the first magnetic core 22 is composed of a plurality of independent first magnetic blocks 22a, 22b, and the assembly method is to use an adhesive layer 33 to combine the plurality of first
  • the magnetic blocks 22a and 22b are bonded together to form a square with a length, width, and thickness of 90 mm, 60 mm, and 50 mm, as shown in FIG. 2a.
  • the material of the adhesive layer 33 may be a single-liquid type epoxy resin adhesive (EPORITE 2089).
  • first magnetic core 22 in this embodiment is composed of two first magnetic blocks 22a, 22b, the present invention is not limited to the number of multiple first magnetic blocks; In another embodiment (as the third embodiment will be described later), the first magnetic core 22 may be an integrally formed magnetic core block without any adhesive layer.
  • the second magnetic core 55 may be an integrally formed block having a hollow portion for receiving the first magnetic core 22 therein, as shown in FIGS. 2a and 2b. Therefore, the shape and volume of the hollow portion of the second magnetic core 55 are determined by the shape and volume of the first magnetic core 22. Furthermore, the size and shape of the first magnetic core 22 and the second magnetic core 55 must be determined in accordance with the design details of the filter inductor 200 regarding the shape or volume. In this embodiment, the shapes of the first magnetic core 22 and the second magnetic core 55, and the shape of the hollow portion of the second magnetic core 55 are all a square; however, the invention is not limited to the first magnetic core 22 and the second The size and shape of the magnetic core 55.
  • the first magnetic core 22 is composed of a first magnetic material
  • the second magnetic core 55 is composed of a second magnetic material
  • the second magnetic material is different from the first magnetic material.
  • the first magnetic material and the second magnetic material it is necessary to consider whether the two materials can be at a certain frequency for the effect of eliminating common mode and/or differential mode noise and electromagnetic interference Good results are achieved within the range; that is, the first magnetic material and the second magnetic material are selected to effectively eliminate noise and electromagnetic interference in a first frequency range and a second frequency range, respectively
  • the first frequency range is different from the second frequency range; preferably, the union of the first frequency range and the second frequency range is a full frequency range between 1K Hz and 1000M Hz.
  • the three magnetic cores are each composed of different magnetic materials, each of which can effectively eliminate noise and electromagnetic interference in three frequency ranges , And the union of the three frequency ranges is the full frequency range.
  • the filter inductor 200 can eliminate common mode and/or differential mode noise and electromagnetic interference in the full frequency range.
  • the respective magnetic materials of the plurality of magnetic cores can be selected from the following soft magnetic materials: ferrite Ferrite, amorphous soft magnetic, iron powder, etc.
  • the first magnetic material is NiZn ferrite, due to its high impedance in the first frequency range (eg, a high frequency range between 1K and 30M Hz) Characteristics, the first magnetic core 22 can effectively attenuate common mode and/or differential mode noise in the first frequency range and provide a good effect of eliminating electromagnetic interference;
  • the second magnetic material is manganese zinc ferrite MnZn ferrite, due to its high conductivity in the second frequency range (for example, a low frequency range between 30M and 1000M Hz), the second magnetic core 55 can be in the second frequency range Noise is effectively attenuated within.
  • a single filter inductor 200 can achieve the full frequency range (ie Including the above requirements for eliminating noise and electromagnetic interference in the first frequency range and the second frequency range).
  • the filter inductor 200 further includes a first fastening device and/or a second fastening device for fixing at least one magnetic core of the plurality of magnetic cores.
  • the filter inductor 200 includes the first fastening device and the second fastening device for fixing the second magnetic core 55 and the first magnetic core 22, respectively, and thus can The electromagnetic interference between the first magnetic core 22 and the second magnetic core 55 is avoided.
  • the first fastening device includes at least one first rib 81, and at least one first groove opposite to the at least one first rib 81; the at least one first rib 81 is disposed on the housing At least one inner wall of 44 corresponds to the at least one first groove provided on the surface of the second magnetic core 55.
  • the second fastening device includes at least one second rib 82 and at least one second groove opposite to the at least one second rib 82; the at least one second rib 82 is disposed on at least one outer wall of the at least one conductor channel 101 , And corresponds to the at least one second groove provided on the surface of the portion where the first magnetic core 22 contacts the at least one conductor channel 101.
  • At least one first groove included in the first fastening device is disposed on at least one inner wall of the housing 44, and Corresponding to at least one first rib 81 provided on the surface of the second magnetic core 55; at least one second groove included in the second fastening device is provided on at least one outer wall of the at least one conductor channel 101 and is provided with At least one second rib 82 corresponds to the surface of the portion where the first magnetic core 22 contacts the at least one conductor channel 101.
  • FIG. 3a and 3b, 4a and 4b, and 5a and 5b are schematic cross-sectional views of the second, third, and fourth embodiments of the filter inductor 200 of the present invention, respectively.
  • the second, third, and fourth embodiments have components with the same name and the same number as in the first embodiment. The functions of these components are similar or the same. They have been explained in the above description of the first embodiment, so they are not Repeat again.
  • the difference between the second embodiment and the first embodiment lies in the shapes of the first magnetic core 22 and the second magnetic core 55.
  • the shapes of the first magnetic core 22 and the second magnetic core 55 of the second embodiment, and the shape of the hollow portion of the second magnetic core 55 are both a cylindrical shape, and the shape of the first embodiment is a square shape different.
  • the hollow portions of the first magnetic core 22, the second magnetic core 55, and the second magnetic core may be an elliptical cylinder or a triangular cylinder.
  • the shapes of the first magnetic core 22 in the third embodiment and the first embodiment are the same and are all a square, and the difference lies in whether the first magnetic core 22 is integrally formed.
  • the first magnetic core 22 of the third embodiment is an integrally formed magnetic core block, and the first magnetic core 22 of the first embodiment is to bond a plurality of separated first magnetic blocks 22a, 22b by using an adhesive layer 33 And composed.
  • the shapes of the second magnetic core 55 of the fourth embodiment and the first embodiment are the same, and they are both a block with a hollow portion, and the hollow portion is used to accommodate the first magnetic core 22.
  • the difference between the fourth embodiment and the first embodiment is that the second magnetic core 55 of the fourth embodiment includes a plurality of independent second magnetic blocks 55a, 55b, and the second magnetic block 55a, 55b is bonded, however, the second magnetic core 55 of the first embodiment is an integrally formed core block, and it is not necessary to use any adhesive layer for bonding. Therefore, although the second magnetic core 55 in the fourth embodiment is composed of two second magnetic blocks 55a, 55b, the present invention is not limited to the number of the plurality of second magnetic blocks 55.
  • the prior art needs to install a plurality of filter inductors on the input end of a high-power power module to eliminate noise and electromagnetic interference in the full frequency range.
  • the advantage of the present invention is that it only needs to be installed
  • a filter inductor of the present invention can achieve the above-mentioned effects; on the other hand, precisely because a high-power power module no longer needs to have multiple filter inductors, the filter inductor of the present invention can reduce the high-power power supply The manufacturing cost of the module and the high-power power system to which it belongs, and can reduce the volume of the high-power power module, and its power density is higher.

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Abstract

一种电子设备与滤波电感器 (200)，滤波电感器可被装设于一电子设备的一输入端；该滤波电感器(200)包括多个磁芯与至少一导体，该多个磁芯包括一第一磁芯(22)与一第二磁芯(55)，其中该至少一导体嵌入该第一磁芯(22)内；该第二磁芯(55)有一中空部分，用以容纳该第一磁芯(22)，其中该第一磁芯(22)是由一第一磁性材质构成，而该第二磁芯(55)是由一第二磁性材质构成，该第二磁性材质不同于该第一磁性材质。

Description

电子设备与其滤波电感器 技术领域
本发明涉及一电子设备，尤其涉及一电子设备的一滤波电感器(filter inductor)。
背景技术
一高功率电力系统通常具备一高功率电源模块，例如一转换器(converter)模块或一逆变器(inverter)模块。这类电源模块在全频率范围或至少是某些频率范围内，通常无法满足国际无线电干扰特别委员会(CISPR，法语原名为Comité International Spécial des Perturbations Radioélectriques)对于电磁干扰现象(electromagnetic interference，简称EMI)的监管标准和其他标准，尤其是在电动汽车(electric vehicle，简称EV)或是油电混合动力车(hybrid electric vehicle，简称HEV)的驱动系统所需的频率范围和/或一高频范围内。因此，在这类高功率电源模块的输入端需设置多个各自使用不同磁性材质的滤波电感器，用以滤除在全频范围内的共模(common-mode，简称CM)和差模(differential-mode，简称DM)噪声与消除电磁干扰。
图1是现有技术中的一滤波电感器100的一切面示意图。滤波电感器100设置在一高功率电力系统具有的一高功率电源模块的输入端。滤波电感器100包括一外壳41、一磁芯26、两条分别为正负的母线(busbar)11、一中心柱202、一侧柱201、一中央空隙65与至少一侧边空隙。两条母线11嵌在磁芯26里，且将磁芯26区分成中心柱202与侧柱201。中心柱202位于两条母线11之间，磁芯26的其余部分则为侧柱201。中央空隙45与该至少一侧边空隙各自位于中心柱202与侧柱201内，如此，形成了如图1所示的一个，由滤波电感器100的切面看来是近似于一H型的结构。为了便于形成上述结构与元件组装，磁芯26由多个独立的磁块26a、26b所组成，组装方式为使用一黏合层(adhesive layer)33将磁块26a、26b黏合在一起。黏合层33的材质可为单液型环氧树脂黏着剂(EPORITE 2089)。
外壳41用以容纳磁芯26与母线11，因此外壳41的容积与形状的设计，须配合磁芯26与两条母线11各自的体积与形状。此外，为了便于元件组装，外壳41可由多个外壳部件组成，例如本实施例中的一上半部壳体41a与一下半部壳体41b。
磁芯26的材料为一种磁性材质，可由以下几种软磁材料中选取一种来使用：铁氧体(ferrite)、非晶软磁(amorphous soft magnetic material)和铁粉。若磁芯26的材质是锰锌铁氧体(MnZn ferrite)，由于其具有的高磁导率仅适用于一低频范围(例如介于1K与30M赫兹之间)内，滤波电感器100只能用于衰减该低频范围内的共模与差模噪声。相反地，如果选用镍锌铁氧体(NiZn ferrite)作为磁芯26的材质，则由于其在一高频范围(例如介于30M与1000M赫兹之间)内的高组抗的特性，滤波电感器100只能用于衰减该高频范围内的共模与差模噪声与消除电磁干扰。
因此得知，为了能够消除在一全频范围(即涵盖上述该低频范围与该高频范围)内的共模与差模噪声与电磁干扰，仅靠单一个现有技术的滤波电感器是无法施行的，而必须在该高功率电源模块的该输入端设置多个各自使用不同磁性材质的滤波电感器；此外，该多个滤波电感器分别占据该高功率电源模块内部一定的空间，以致于在产品设计规划上，无法缩减该高功率电源模块的整体体积。
发明内容
本发明的目的在于解决上述的技术问题，而提供一种具有多个磁芯的滤波电感器，用以消除在一全频范围内的噪声与电磁干扰。
为实现上述目的，本发明采用如下技术方案：
一种滤波电感器，其可被装设于一电子设备电源模块的一输入端；该滤波电感器包括多个磁芯与至少一导体，该多个磁芯包括一第一磁芯与一第二磁芯，其中该至少一导体嵌入该第一磁芯内；该第二磁芯有一中空部份，用以容纳该第一磁芯，其中该第一磁芯是由一第一磁性材质构成，而该第二磁芯是由一第二磁性材质构成，该第二磁性材质不同于该第一磁性材质。
进一步地，该第一磁性材质与该第二磁性磁性材质，皆可在以下的多种软磁材料中选取：铁氧体(ferrite)、非晶软磁(amorphous soft magnetic material)和铁粉。
进一步地，该第一磁性材质能在一第一频率范围内消除噪声与电磁干扰，而该第二磁性材质能在一第二频率范围内消除噪声与电磁干扰，该第二频率范围不同于该第一频率范围。
进一步地，该第一频率范围与该第二频率范围的并集覆盖了一全频范围，该全频范围介于1K赫兹与1000M赫兹。
进一步地，该第一磁性材质与该第二磁性材质中的其中一个是镍锌铁氧体(NiZn ferrite)，另一个是锰锌铁氧体(MnZn ferrite)。
进一步地，该滤波电感器另包括一外壳，其用以容纳该多个磁芯。
进一步地，该滤波电感器另包括一第一紧固装置，该第一紧固装置用以固定该多个磁芯中的至少一个磁芯。
进一步地，该第一紧固装置包括至少一第一肋，以及与该至少一第一肋相对的至少一第一槽，其中该至少一第一肋设置于该外壳的至少一内壁，并与设置于该第二磁芯的表面的该至少一第一槽相对应；或该至少一第一槽中设置于该外壳的至少一内壁，并与设置于该第二磁芯的表面的该至少一第一肋相对应。
进一步地，该滤波电感器另包括至少一导体通道，该至少一导体通道形成于该第一磁芯的内部，用以让该至少一导体通过。
进一步地，该滤波电感器另包括一第二紧固装置，该第二紧固装置用以固定该多个磁芯中的至少一个磁芯。
进一步地，该第二紧固装置包括至少一第二肋，以及与该至少一第二肋相对的至少一第二槽，其中该至少一第二肋设置于该至少一导体通道的至少一外壁，并与设置于该第一磁芯与该至少一导体通道接触的部分的表面的该至少一第二槽相对应；或该至少一第二槽中设置于该至少一导体通道的至少一外壁，并与设置于该第一磁芯与该至少一导体通道接触的部分的表面的该至少一第二肋相对应。
进一步地，该第一磁芯和该第二磁芯的其中的至少一个，是由多个独立的磁块所组成，组成方式为使用一黏合层(adhesive layer)将该多个磁块黏合在一起。
进一步地，该滤波电感器包括两个导体，该两个导体包括两条各为正负的母线(busbar)，该至少一导体通道包括两个导体通道。
进一步地，该第一磁芯包括一中心柱与一侧柱，该中心柱位于该两个导体通道之间。
进一步地，该滤波电感器包括至少一中央空隙，该至少一中央空隙位于该中心柱内。
本发明亦涉及于一种电子设备，包括上述的滤波电感器。
进一步地，该电子设备为一逆变器(inverter)。
附图说明
图1是现有技术中的一滤波电感器100的一切面示意图。
图2a、图2b和图2c各自是本发明的一滤波电感器200的第一实施例的切面示意图。
图3a和图3b各自是本发明的滤波电感器200的第二实施例的切面示意图。
图4a和图4b各自是本发明的滤波电感器200的第三实施例的切面示意图。
图5a和图5b各自是本发明的滤波电感器200的第四实施例的切面示意图。
具体实施方式
下面结合附图与实施例，对本发明的实质性特点和优势作进行详细说明，但本发明并不局限于所列的实施例。
图2a、图2b和图2c各自是本发明的一滤波电感器200的第一实施例的切面示意图。滤波电感器200设置在一电子设备，例如一高功率电力系统具有的一高功率电源模块的输入端，且具有多个磁芯，用以消除在一全频范围 内的噪声与电磁干扰。该多个磁芯中的至少两个磁芯是由不同于彼此的磁性材质构成的。优选地，该电子设备为一逆变器(inverter)。
于本实施例中，滤波电感器200的该多个磁芯包括一第一磁芯22与一第二磁芯55，而第二磁芯55具有一中空部分，该中空部分用以容纳第一磁芯22。在另一个实施例(未图示)中，滤波电感器200有三个磁芯，由内而外包括一第一磁芯、一第二磁芯与一最外围的第三磁芯，则该第二磁芯与该第三磁芯皆具有一中空部分，分别用以容纳该第一磁芯与该第二磁芯。本发明不受限于该多个磁芯的个数。
进一步地，滤波电感器200另包括一外壳44(如图2c所示)、至少一导体通道101、至少一导体、一中心柱202、至少一中央空隙65、一侧柱201与至少一侧边空隙。该至少一导体通道101形成于(亦可说是镶嵌在)第一磁芯22的内部，用以让该至少一导体通过。于本实施例中，该至少一导体包括两条各自为正负的母线(busbar)，而滤波电感器200具有的两个导体通道101则用以让该两条母线通过。
至于外壳44，其材质可为一塑胶。外壳44用以容纳该多个磁芯(例如本实施例中的第一磁芯22与第二磁芯55)，并且设置有该至少一导体通道101。外壳44的容积与形状的设计，须配合该多个磁芯与该至少一导体通道101的体积与形状。于一实施例中，外壳44的结构可为如同图1的滤波电感器100的外壳41，其可由多个外壳部件组成，例如上半部壳体41a与下半部壳体41b；然而本发明不限于外壳44的实施(例如材质、结构、尺寸与形状等等)。
滤波电感器200的两个导体通道101将第一磁芯22区分成中心柱202与侧柱201，中心柱202位于两个导体通道101之间，其余部分则为侧柱201。该至少一中央空隙65与该至少一侧边空隙则各自位于中心柱202与侧柱201里，且通常是各自位于中心柱202与侧柱201的中间，如此，形成了如图2a所示的一个，由滤波电感器200的切面来看是一近似于H型的结构。该至少一中央空隙65可用以容纳滤波电感器200另具有的一元件，像是一传感器。此外，于另一个实施例中(未图示)，滤波电感器200具有多个位于中心柱202内的中央空隙65。进一步地，在另一些实施例中(未图示)，滤波电感 器200不具有上述的侧边空隙或是具有多个该侧边空隙。本实施例不限于该至少一中央空隙65与该至少一侧边空隙的个数。
进一步地，为了便于形成上述结构与元件组装，第一磁芯22由多个独立的第一磁块22a、22b所组成，组装方式为使用一黏合层(adhesive layer)33将该多个第一磁块22a、22b黏合在一起，组成一个形状为一个长度、宽度、厚度各自为90毫米、60毫米、50毫米的方块，如图2a所示。黏合层33的材质可为的材质可为单液型环氧树脂黏着剂(EPORITE 2089)。另外，虽然本实施例中的第一磁芯22是由两个第一磁块22a、22b组成的，然而本发明不受限于多个第一磁块的个数；除此之外，在另一实施例中(如后面会叙述到的第三实施例)，第一磁芯22可为一个一体成型的磁芯块，无须使用任何黏合层黏合。
第二磁芯55可为一个一体成型且具有一中空部分的方块，该中空部分用以将第一磁芯22容纳于其内，如图2a与图2b所示。也因此，第二磁芯55的该中空部分的形状与体积，是由第一磁芯22的形状与体积来决定的。更进一步地，第一磁芯22和第二磁芯55各自的尺寸与形状，须配合滤波电感器200关于形状或是体积相关的设计细节来决定。于本实施例中，第一磁芯22和第二磁芯55的形状，以及第二磁芯55的该中空部分的形状皆为一方块；然而本发明不限于第一磁芯22和第二磁芯55各自的尺寸与形状。
第一磁芯22由一第一磁性材质构成，而第二磁芯55由一第二磁性材质构成，该第二磁性材质不同于该第一磁性材质。此外，在选取该第一磁性材质与该第二磁性材质时，须考虑这两种材质在对于共模和/或差模躁声与电磁干扰的消除的效果上，是否能够分别在某一个频率范围内达成良好的效果；也就是说，该第一磁性材质与该第二磁性材质被选取用以能分别有效地消除在一第一频率范围与在一第二频率范围内的噪声与电磁干扰，且该第一频率范围不同于该第二频率范围；优选地，该第一频率范围与该第二频率范围的并集为一介于1K赫兹与1000M赫兹的全频范围。
至于在上述提到的具有三个磁芯的实施例(未图示)中，该三个磁芯各由不同的磁性材质构成，各自能有效地消除在三个频率范围内的噪声与电磁干扰，且该三个频率范围的并集，即是该全频范围。如此一来，滤波电感器200便能消除在该全频范围内的共模和/或差模躁声与电磁干扰。
该多个磁芯各自的磁性材质，例如第一磁芯22的该第一磁性材质与第二磁芯55的该第二磁性材质，皆可以从以下的几种软磁材料中选取：铁氧体(ferrite)、非晶软磁(amorphous soft magnetic material)和铁粉等。于本实施例中，该第一磁性材质是镍锌铁氧体(NiZn ferrite)，由于其在该第一频率范围(例如介于1K与30M赫兹之间的一高频范围)内的高阻抗的特性，因此第一磁芯22可在该第一频率范围内有效地使共模和/或差模噪声衰减与提供良好的消除电磁干扰的效果；该第二磁性材质则是锰锌铁氧体(MnZn ferrite)，由于其在该第二频率范围(例如介于30M与1000M赫兹之间的一低频范围)内的高传导率的特性，因此第二磁芯55可在该第二频率范围内有效地使噪声衰减。
如此，利用第一磁芯22和第二磁芯55各自不同的磁性材质分别在该高频范围和在该低频范围内的特性，单一个滤波电感器200即能达成在该全频范围(即包括上述的该第一频率范围与该第二频率范围)内对于消除噪声与电磁干扰的要求。
优选地，滤波电感器200另包括一第一紧固装置和/或一第二紧固装置，用以固定该多个磁芯中的至少一个磁芯。于图2c所示的本实施例中，滤波电感器200包括该第一紧固装置与该第二紧固装置，分别用以固定第二磁芯55与固定第一磁芯22，且因此可避免第一磁芯22和第二磁芯55之间的相互间的电磁干扰。
进一步地，如图2c所示，该第一紧固装置包括至少一第一肋81，以及与该至少一第一肋81相对的至少一第一槽；该至少一第一肋81设置于外壳44的至少一内壁，并与设置于第二磁芯55的表面的该至少一第一槽相对应。该第二紧固装置包括至少一第二肋82，以及与该至少一第二肋82相对的至少一第二槽；该至少一第二肋82设置于该至少一导体通道101的至少一外壁，并与设置于第一磁芯22与该至少一导体通道101接触的部分的表面的该至少一第二槽相对应。
于另一实施例(未图示)中，上述的肋与槽的位置对调，也就是说，该第一紧固装置所包括的至少一第一槽设置于该外壳44的至少一内壁，并与设置于第二磁芯55的表面的至少一第一肋81相对应；该第二紧固装置所包括的至少一第二槽设置于该至少一导体通道101的至少一外壁，并与设置于第 一磁芯22与该至少一导体通道101接触的部分的表面的至少一第二肋82相对应。
图3a和图3b、图4a和图4b、图5a和图5b分别是本发明的滤波电感器200的第二、第三以及第四实施例的切面示意图。第二、第三以及第四实施例中具有与第一实施例中同名且同编号的元件，该些元件的功能相似或相同，已于上述对于第一实施例的描述中解说过，故不再赘叙。
第二实施例和第一实施例之间的区别，在于第一磁芯22和第二磁芯55的形状。第二实施例的第一磁芯22和第二磁芯55的形状，以及第二磁芯55的该中空部分的形状皆为一圆柱状，与第一实施例的皆为方块状的形状不同。而于另一些实施例(未图示)中，第一磁芯22、第二磁芯55与第二磁芯的该中空部分，可为一椭圆柱或一三角柱状。
第三实施例和第一实施例的第一磁芯22的形状皆相同，皆为一方块，而区别在于第一磁芯22是否是一体成形。第三实施例的第一磁芯22是一个一体成形的磁芯块，而第一实施例的第一磁芯22是通过使用一黏合层33将多个分离的第一磁块22a、22b黏合而组成。
第四实施例和第一实施例的第二磁芯55的形状皆相同，皆为一具有中空部分的方块，该中空部分用以容纳第一磁芯22。第四实施例和第一实施例的区别，在于第四实施例的第二磁芯55包括多个独立的第二磁块55a、55b，并通过使用一黏合层33将第二磁块55a、55b黏合，然而第一实施例的第二磁芯55是一个一体成形的磁芯块，无须使用任何黏合层黏合。因此，虽然第四实施例中的第二磁芯55是由两个第二磁块55a、55b组成的，然而本发明不受限于多个第二磁块55的个数。
与现有技术相比，现有技术需要在一高功率功率模块的输入端安装多个滤波电感器以消除在全频范围内的噪声与电磁干扰，然而本发明的优点即在于，只须要设置一个本发明的滤波电感器，即能达成上述的功效；另一方面，正是因为一高功率电源模块不再需要具有多个滤波电感器，所以本发明的滤波电感器能降低该高功率电源模块以及与其所属的高功率电力系统的制造成本，并且能缩小该高功率电源模块的体积，且其功率密度更高。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润 饰，这些改进和润饰也应视为本发明的保护范围。

Claims (17)

  1. 一种滤波电感器(200)，其可被装设于电子设备的输入端；所述滤波电感器(200)包括第一磁芯(22)与至少一导体，所述至少一导体设置在所述第一磁芯(22)内；所述滤波电感器(200)特征在于，包括：
    -多个磁芯，其至少包括有所述第一磁芯(22)与第二磁芯(55)，所述第二磁芯(55)有中空部份，用以容纳所述第一磁芯(22)，其中所述第一磁芯(22)是由第一磁性材质构成，而所述第二磁芯(55)是由第二磁性材质构成，所述第二磁性材质不同于所述第一磁性材质。
  2. 根据权利要求1所述的滤波电感器(200)，其特征在于：所述第一磁性材质与所述第二磁性磁性材质，皆可在以下的多种软磁材料中选取：铁氧体、非晶软磁和铁粉。
  3. 根据权利要求2所述的滤波电感器(200)，其特征在于：所述第一磁性材质能在第一频率范围内消除噪声与电磁干扰，而所述第二磁性材质能在第二频率范围内消除噪声与电磁干扰，所述第二频率范围不同于所述第一频率范围。
  4. 根据权利要求3所述的滤波电感器(200)，其特征在于：所述第一频率范围与所述第二频率范围的并集覆盖了全频范围，所述全频范围介于1K赫兹与1000M赫兹。
  5. 根据权利要求1所述的滤波电感器(200)，其特征在于：所述第一磁性材质与所述第二磁性材质中的其中一个是镍锌铁氧体，另一个是锰锌铁氧体。
  6. 根据权利要求1所述的滤波电感器(200)，其特征在于：所述滤波电感器(200)另包括外壳(44)，其用以容纳所述多个磁芯。
  7. 根据权利要求6所述的滤波电感器(200)，其特征在于：所述滤波电感器(200)另包括第一紧固装置，所述第一紧固装置用以固定所述多个磁芯中的至少一个磁芯(55)。
  8. 根据权利要求7所述的滤波电感器(200)，其特征在于：所述第一紧固装置包括至少一第一肋(81)，以及与所述至少一第一肋(81)相对的至少一第一槽，其中:
    -所述至少一第一肋(81)设置于所述外壳(44)的至少一内壁，并与设置于所述第二磁芯(55)的表面的所述至少一第一槽相对应；或
    -所述至少一第一槽设置于所述外壳(44)的至少一内壁，并与设置于所述第二磁芯(55)的表面的所述至少一第一肋(81)相对应。
  9. 根据权利要求1所述的滤波电感器(200)，其特征在于：所述滤波电感器(200)另包括至少一导体通道(101)，所述至少一导体通道(101)形成于所述第一磁芯(22)的内部，用以让所述至少一导体通过。
  10. 根据权利要求9所述的滤波电感器(200)，其特征在于：所述滤波电感器(200)另包括第二紧固装置，所述第二紧固装置用以固定所述多个磁芯中的至少一个磁芯(22)。
  11. 根据权利要求10所述的滤波电感器(200)，其特征在于：所述第二紧固装置包括至少一第二肋(82)，以及与所述至少一第二肋(82)相对的至少一第二槽，其中：
    -所述至少一第二肋(82)设置于所述至少一导体通道(101)的至少一外壁，并与设置于所述第一磁芯(22)与所述至少一导体通道(101)接触的部分的表面的所述至少一第二槽相对应；或
    -所述至少一第二槽设置于所述至少一导体通道(101)的至少一外壁，并与设置于所述第一磁芯(22)与所述至少一导体通道(101)接触的部分的表面的所述至少一第二肋(82)相对应。
  12. 根据权利要求1所述的滤波电感器(200)，其特征在于：所述第一磁芯(22)和所述第二磁芯(55)的其中的至少一个，是由多个独立的磁块所组成，组成方式为使用黏合层(33)将所述多个磁块黏合在一起。
  13. 根据权利要求9所述的滤波电感器(200)，其特征在于：所述滤波电感器(200)包括两个导体，所述两个导体包括两条各为正负的母线，所述至少一导体通道包括两个导体通道(101)。
  14. 根据权利要求13所述的滤波电感器(200)，其特征在于：所述第一磁芯(22)包括中心柱(202)与侧柱(201)，所述中心柱(202)位于所述两个导体通道(101)之间。
  15. 根据权利要求14所述的滤波电感器(200)，其特征在于：所述滤波电感器(200)包括至少一中央空隙(65)，所述至少一中央空隙(65)位于所述中心柱(202)内。
  16. 一种电子设备，其特征在于，包括如权利要求1到15中任一权利要求所述的滤波电感器(200)。
  17. [根据细则91更正 17.02.2020]　
    根据权利要求16所述的电子设备，其特征在于：所述电子设备为逆变器。
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