CN115621010A

CN115621010A - High-power inductor

Info

Publication number: CN115621010A
Application number: CN202211344151.XA
Authority: CN
Inventors: 王刚; 李爱青; 刘晓宇
Original assignee: Sengen Technology Suzhou Co ltd
Current assignee: Sengen Technology Suzhou Co ltd
Priority date: 2022-10-31
Filing date: 2022-10-31
Publication date: 2023-01-17

Abstract

The application discloses high-power inductance, this high-power inductance including be the magnetic core subassembly of closed loop and wear to locate the conductor subassembly of the closed loop space of magnetic core subassembly, the conductor subassembly is including the first conductor that has both ends and the second conductor that has both ends, and wherein one end of first conductor is from the magnetic core subassembly outside the bending of turning back and the corresponding end of second conductor connect as an organic wholely each other. One end of the first conductor is bent back from the outer side of the magnetic core assembly and the corresponding end of the second conductor is connected with each other to form a whole linear conductor assembly, so that the winding effect of the conductor assembly in a limited space is realized, the geometric series inductance is multiplied by the winding, the problem of non-ideal inductance of a magnetic ring is solved, and the space and the cost are saved.

Description

High-power inductor

Technical Field

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

Background

The inductor can convert electric energy into magnetic energy to be stored, and consists of a magnetic core and a winding. The inductance of the toroidal inductor depends on the inductance of the magnetic core and the number of turns of the winding, and is calculated according to the following formula:

l = AL × N, wherein:

inductance of L-ring inductor

Inductance of AL-core

N-number of turns of winding

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

As shown in fig. 1, the toroidal inductor includes a toroidal core and a winding wound around the toroidal core. In order to pass large-flow current, the winding of the high-power inductor is often large in wire diameter, but the current-carrying capacity of a multi-strand flexible wire is limited, so that a bus of the high-power inductor is usually a copper bar with a rectangular cross section. As shown in fig. 2, in the prior art, a high-power inductor often passes through an annular magnetic core directly through a copper bar, and the inductance of the straight-through inductor is only the inductance of one magnetic ring, which is far from the ideal inductance.

The copper bar is hard under normal conditions, and is difficult to be wound on the magnetic ring randomly like a plurality of strands of flexible wires to form a multi-turn structure. However, the current-carrying capacity of the cord is limited, and the flexible diameter needs to be increased if a large current is to be passed. However, when the diameter of the cord is increased, the hardness of the cord is increased, and it is difficult to wind a wire having a high hardness around the core. At present, with the increasing demand of the inductor in a large-current scene, the copper bar can become a preferred scheme of a conductor of the high-power inductor through large-flow current, but the multi-turn structure of the copper bar is difficult to realize, so that the inductance of the high-power inductor cannot reach ideal inductance.

Disclosure of Invention

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

The application provides a high-power inductance adopts following technical scheme:

a high-power inductor comprises a magnetic core assembly in a closed loop and a conductor assembly penetrating through the closed loop space of the magnetic core assembly, wherein the conductor assembly comprises a first conductor with two ends and a second conductor with two ends, one end of the first conductor is bent back from the outer side of the magnetic core assembly, and the corresponding ends of the second conductor are connected into a whole.

By adopting the technical scheme, the conductor assembly serving as the winding consists of the first conductor and the second conductor, after the first conductor and the second conductor pass through the closed loop space of the magnetic core assembly, one end of the first conductor is bent back and bent from the outer side of the magnetic core assembly and the corresponding end of the second conductor are connected with each other to form a whole linear conductor assembly, the winding effect of the conductor assembly in a limited space is realized, the inductance of the winding in geometric progression is multiplied, the problem of non-ideal inductance of a magnetic ring is solved, and the space and the cost are saved.

Optionally, the end of the second conductor connected to the first conductor extends along the radial direction of the magnetic core assembly and turns around to avoid the end of the first conductor located inside the magnetic core assembly to reach the end of the first conductor located outside the magnetic core assembly, so as to connect to the corresponding end of the first conductor, and the first conductor and the second conductor form a layer of turns after being connected.

By adopting the technical scheme, because the wire diameter of the conductor assembly of the high-power inductor is larger, the space of the closed loop space of the magnetic core assembly is limited, and the first conductor and the second conductor can be partially overlapped or completely overlapped when penetrating through the closed loop space of the magnetic core assembly, so that when one end of the first conductor is bent back from the outer side of the magnetic core assembly and is connected with the corresponding end of the second conductor, the second conductor can be interfered by the first conductor. According to the technical scheme, the second conductor extends along the radial direction of the magnetic core assembly and revolves to avoid the interference of the first conductor, so that the connection with the first conductor is realized, the turn winding effect of the conductor assembly in a limited space is realized, the problem of non-ideal inductance of a magnetic ring is solved, and the space and the cost are saved.

Optionally, the magnetic core assembly is in a circular or elliptical ring shape or a race track type ring shape or a square tube shape.

By adopting the technical scheme, the circular, oval ring-shaped, runway-shaped and square-tube-shaped magnetic cores are all provided with the ring walls for the winding of the conductor assembly.

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

By adopting the technical scheme, the flow of the current which can pass through the first conductor and the second conductor is increased.

Optionally, the first conductor and the second conductor are surface-bent turns perpendicular to a thickness direction, wherein the thickness direction is a length direction of the shortest side of the first conductor and the second conductor (22).

By adopting the technical scheme, when the conductor with the rectangular cross section is wound, the surface perpendicular to the thickness direction is bent to wind the turn, so that the specification of the conductor assembly capable of being wound is improved as much as possible in a limited space, and the flow of current capable of passing through the first conductor and the second conductor is increased.

Optionally, a surface of the first conductor perpendicular to the thickness direction is connected to a surface of the second conductor perpendicular to the thickness direction, where the surface perpendicular to the thickness direction is a surface perpendicular to the shortest side of the first conductor and the second conductor.

By adopting the technical scheme, the circulation path of the current from the first conductor to the second conductor is increased, so that the current with larger flow is circulated.

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

By adopting the technical scheme, besides the first conductor and the second conductor, the magnetic core assembly is provided with a larger number of conductors with the same connection characteristics, and the conductors are connected with each other to form a turn winding structure with more than two turns. The conductor assembly forms multi-turn winding, and inductance of the high-power inductor is improved.

Optionally, the conductor assemblies are symmetrically arranged on the magnetic core assembly.

By adopting the technical scheme, the 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 bent back from the outer side of the magnetic core assembly and the corresponding end of the second conductor is connected with each other to form a whole linear conductor assembly, so that the winding effect of the conductor assembly in a limited space is realized, the geometric series inductance is multiplied by the winding, the problem of non-ideal inductance of a magnetic ring is solved, and the space and the cost are saved.

2. The connection with the first conductor is achieved by the second conductor extending in a radial direction of the core assembly and turning around to avoid interference with the first conductor.

Drawings

Fig. 1 is a schematic structural diagram of a toroidal 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 diagram of the structure of the conductor assembly.

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

Description of reference numerals: 1. a magnetic core assembly; 2. a conductor assembly; 21. a first conductor; 22. a second conductor; 23. a U-shaped connecting end; 24. a first pin; 25. a second pin.

Detailed Description

The present application is described in further detail below with reference to the attached drawings.

The embodiment of the application discloses a high-power inductor. Referring to fig. 3, the high power inductor includes a magnetic core assembly 1 and a conductor assembly 2, the magnetic core assembly 1 is ring-shaped, the conductor assembly 2 is used for conducting current, and the conductor assembly 2 is bent and wound on a ring wall of the magnetic core assembly 1.

In different embodiments, the core assembly 1 may include different numbers of ring cores, the number of ring cores may be set according to the inductance of the required high-power inductor, one ring core may be provided, or a plurality of ring cores may be provided, and if a plurality of ring cores are provided, the plurality of ring cores may be coaxially provided (not shown in the figure). In different embodiments, the magnetic core may have different ring shapes, but any shape may be formed with a ring wall around which the conductor assembly 2 is wound, and the magnetic core may have a circular shape, an elliptical ring shape, a race-track ring shape, or a square tube shape.

The conductor assembly 2 is used to conduct current. In various embodiments, the conductor assembly 2 may be made of different materials, but it is sufficient that the conductor assembly 2 has excellent conductivity, and the conductor assembly 2 may be made of copper as an example, because copper metal has excellent conductivity and is easily processed into a rectangular plate-shaped conductor.

Referring to fig. 3 and 4, in different embodiments, the conductor assembly 2 may be wound around the annular wall of the magnetic core assembly 1 in different manners, and as an example, the conductor assembly 2 includes a first conductor 21 having two ends and a second conductor 22 having two ends, and the first conductor 21 and the second conductor 22 are both disposed 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 unit 1 to form a U-shaped conductor, and the second conductor 22 is connected to one end of the first conductor 21 located outside the magnetic core unit 1. Specifically, one end of the first conductor 21 located inside the magnetic core assembly 1 extends in the axial direction of the magnetic core assembly 1 toward the direction away from the magnetic core assembly 1, and the extension portion is formed with a first pin 24 of an inductor. So set up, the electric current can flow in first conductor 21 through first pin 24 to penetrate behind the closed circuit of magnetic core subassembly 1, again along the closed circuit of the outflow magnetic core subassembly 1 of first conductor 21, later again via the closed circuit of second conductor 22 inflow magnetic core subassembly 1, wear out the closed circuit of magnetic core subassembly 1 via second conductor 22 at last, accomplish electric current and wind circle.

Referring to fig. 3 and 5, the second conductor 22 is connected to the first conductor 21, but in different embodiments, the end of the second conductor 22 connected to the first conductor 21 may have different shapes, but may be connected to the first conductor 21 and avoid interference of the first conductor 21, and as an example, the end of the second conductor 22 connected to the second conductor 22 extends in the radial direction of the magnetic core assembly 1 and is bent to form a U-shaped connection end 23, and the end of the first conductor 21 located inside the magnetic core assembly 1 is inserted into a gap of the U-shaped connection end 23. By the arrangement, the second conductor 22 avoids the interference of the first conductor 21, and is connected with the first conductor 21, so that the winding of the conductor assembly 2 in a limited space is realized, the problem of non-ideal inductance of a magnetic ring is solved, and the space cost is saved. Referring to fig. 1, specifically, one end of the second conductor 22 away from the U-shaped connecting end 23 extends along the axial direction of the magnetic core assembly 1 toward the direction away from the magnetic core assembly 1, and the extending portion is formed with a second pin 25 of the inductor.

It should be noted that the first conductor 21 and the second conductor 22 are pre-processed into a curved shape before assembly, the shape of the first conductor 21 is matched with the shape of the second conductor 22, and the size of the first conductor 21 is matched with the size of the second conductor 22 to ensure that the first conductor 21 and the second conductor do not interfere with each other and the magnetic core assembly 1 after winding. So that the corresponding ends of the two can be directly combined without processing the shapes on site after combination, and the high-power inductor can be easily realized in large-scale production and manufacturing. The first conductor 21 and the second conductor 22 are preprocessed before assembly, so that the structural size is accurate, and the processing cost is low. The following description will also assume by default that the dimensions of the first conductor 21 and the dimensions of the second conductor 22 are calculated by design in advance and are preprocessed.

Referring to fig. 3 and 4, in order to increase the size of the windable conductor assembly 2 as much as possible in a limited space to increase the current that can pass through the inductor, a specific but non-limiting structure is proposed in which the magnetic core assembly 1 has an elliptical ring shape, the first conductor 21 and the second conductor 22 have rectangular cross sections, the first conductor 21 and the second conductor 22 are each bent at a plane perpendicular to the thickness direction, and the second conductor 22 is disposed with respect to a portion of the first conductor 21 that is located inside the magnetic core assembly 1. In a limited space, the thickness and width of the first conductor 21 and the thickness and width of the second conductor 22 are increased as much as possible, so that the current flow path can be increased, and the flux of the current passing through the first conductor 21 and the second conductor 22 can be increased. Specifically, in order to increase the flow path of the current flowing from the first conductor 21 to the second conductor 22, the surface of the second conductor 22 perpendicular to the thickness direction at the end connected to the first conductor 21 is bonded to the surface of the first conductor 21 perpendicular to the thickness direction, so that the contact area between the first conductor 21 and the second conductor 22 is increased, and the current flux flowing from the first conductor 21 to the second conductor 22 is increased.

In order to increase the inductance of the high power inductor, the core assembly 1 may be provided with a plurality of conductor assemblies 2, the plurality of conductor assemblies 2 are connected in series (not shown in the figure), that is, the core assembly 1 is connected to each other by a larger number of conductors with the same connection characteristics, besides the first conductor 21 and the second conductor 22, and a winding structure with more than two turns is formed. The number of conductor assemblies 2 is set according to the inductance of the high power inductor required. Specifically, the conductor assembly 2 may form two winding structures, and the two winding structures are arranged on two opposite portions of the magnetic core assembly 1 in a mirror image manner and form a common mode inductor.

The above embodiments are preferred embodiments of the present application, and the protection scope of the present application is not limited by the above embodiments, so: equivalent changes in structure, shape and principle of the present application shall be covered by the protection scope of the present application.

Claims

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).