CN221407002U - Modularized inductor - Google Patents

Abstract

The utility model discloses a modularized inductor which comprises a coil, a plurality of inner modules and a plurality of outer modules, wherein the inner modules and the outer modules all comprise soft magnetic materials, the coil is wound on one of the inner modules, the inner modules are mutually spliced to form an inductor inner structure, and the outer modules are spliced on the outer side of the inductor inner structure to wrap the coil and the inner modules. The modularized inductor provided by the utility model can realize a rolling spray-free process and ensure better product performance.

Description

Modularized inductor

Technical Field

The utility model relates to the technical field of inductors, in particular to a modularized inductor.

Background

The inductance industry has been an important component in the field of electronic components. The inductor plays key roles in the circuit such as energy storage, filtering, inductive coupling and the like. With the continuous emergence of new materials and new processes, the inductor industry is also continuously trying to adopt more advanced materials and manufacturing processes to improve performance, reduce cost and promote industry innovation.

The current inductor is usually molded integrally to obtain an integrally formed power inductor, and the internal and external materials of the product are the same. However, such inductances generally have the following problems: (1) When carbonyl iron powder is used as a base material, paint spraying and coating treatment is required to be carried out on the outside of the product to avoid the rust phenomenon of the product, so that the preparation cost is increased. (2) When iron-silicon-chromium alloy iron powder is used as a base material, the product is difficult to rust because the material contains chromium, and the product has relatively low iron content, so that the comprehensive electrical property of the product is reduced, and development requirements are difficult to meet although the rolling spraying procedure is omitted to save the production cost.

The foregoing background is only for the purpose of facilitating an understanding of the principles and concepts of the utility model and is not necessarily in the prior art to the present application and is not intended to be used as an admission that such background is not entitled to antedate such novelty and creativity by virtue of prior utility model or that it is already disclosed at the date of filing of this application.

Disclosure of utility model

In order to solve the technical problems, the utility model provides the modularized inductor which can realize a rolling spray-free process and ensure better product performance.

In order to achieve the above purpose, the present utility model adopts the following technical scheme:

The utility model discloses a modularized inductor which comprises a coil, a plurality of inner modules and a plurality of outer modules, wherein the inner modules and the outer modules all comprise soft magnetic materials, the coil is wound on one of the inner modules, the inner modules are mutually spliced to form an inductor inner structure, and the outer modules are spliced on the outer side of the inductor inner structure to wrap the coil and the inner modules.

Preferably, insulation layers are respectively provided between the inner modules, between the outer modules, and between the inner modules and the outer modules.

Preferably, the insulating layer is formed of glue.

Preferably, the inner module around which the coil is wound is of a cylindrical structure, the other inner modules are of a cuboid or cubic structure, and the outer module is of a cuboid or cubic structure.

Preferably, the other internal modules are spliced to each other on the outer side of the internal module around which the coil is wound to form an inductance internal structure.

Preferably, the inner module and the outer module are both modules pressed from soft magnetic material.

Preferably, the modularized inductor is a structure formed by pressing a plurality of the outer modules around the outside of the coil and the plurality of the inner modules.

Preferably, the inner module and the outer module are both modules pressed from a mixed material of soft magnetic material and glue.

Preferably, the soft magnetic material used for compression molding the inner module is carboxyl iron powder, and the soft magnetic material used for compression molding the outer module is ferrosilicon chromium alloy or carboxyl iron powder.

Preferably, the glue comprises an epoxy resin and a silane coupling agent.

Compared with the prior art, the utility model has the beneficial effects that: according to the modularized inductor disclosed by the utility model, the modularized inductor is formed by splicing each internal module and each external module, so that a product can be flexibly designed according to requirements, and meanwhile, various performance indexes are met; not only can the rolling spray process be realized, but also better product performance can be ensured. In the actual manufacturing process, the module can be formed by pressing soft magnetic materials first so as to achieve higher density, and the insulating layer of the copper wire is not damaged when the soft magnetic materials and the coil are prepared together.

Drawings

Fig. 1 is a top view of the internal structure of a modular inductor according to a preferred embodiment of the present utility model;

Fig. 2 is a side view of the internal structure of a modular inductor according to a preferred embodiment of the present utility model;

Fig. 3 is an axial view of the internal structure of the modular inductor according to the preferred embodiment of the present utility model.

Detailed Description

The following describes embodiments of the present utility model in detail. It should be emphasized that the following description is merely exemplary in nature and is in no way intended to limit the scope of the utility model or its applications.

It will be understood that when an element is referred to as being "mounted" or "disposed" on another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element. In addition, the connection may be for both the fixing action and the circuit/signal communication action.

It is to be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are merely for convenience in describing embodiments of the utility model and to simplify the description by referring to the figures, rather than to indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus are not to be construed as limiting the utility model.

Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the embodiments of the present utility model, the meaning of "plurality" is two or more, unless explicitly defined otherwise.

As shown in fig. 1 to 3, the present utility model discloses a modularized inductor, which comprises a coil 10, a plurality of inner modules 20 and a plurality of outer modules 30, wherein each of the inner modules 20 and the outer modules 30 comprises soft magnetic materials, the coil 10 is wound on one of the inner modules 20, the inner modules 20 are spliced with each other to form an inductor inner structure, the outer modules 30 are spliced on the outer side of the inductor inner structure to form a containing cavity for containing the inductor inner structure, and the containing cavity is used for containing the coil 10 and the inner modules 20, namely, the outer modules 30 are spliced to wrap the coil 10 and the inner modules 20.

The internal module 20 wound with the coil 10 has a cylindrical structure, and the other internal modules 20 have a rectangular or cubic structure, wherein the other internal modules 20 are spliced with each other at the outer side of the internal module 20 wound with the coil 10 to form an inductance internal structure. In addition, the external module 30 is also of a rectangular or cubic structure.

Insulation layers (not shown) formed of glue are provided between the respective inner modules 20, between the respective outer modules 30, and between the inner modules 20 and the outer modules 30, respectively.

In some embodiments, the inner module 20 and the outer module 30 are both modules that are compression molded from soft magnetic material.

In some embodiments, the modular inductor is a structure that is compression molded when a plurality of outer modules 30 are wrapped around the outside of the coil 10 and a plurality of inner modules 20, wherein both the inner modules 20 and the outer modules 30 are modules compression molded from a hybrid material of soft magnetic material and glue.

Wherein, the soft magnetic material adopted by the inner module 20 is carboxyl iron powder, and the soft magnetic material adopted by the outer module 30 is ferrosilicon chromium alloy or carboxyl iron powder; the carboxyl iron powder is iron powder composed of iron and carbon oxide (carbonyl), the ferrosilicon-chromium alloy is alloy composed of iron (Fe), silicon (Si) and chromium (Cr), and the chromium can improve the corrosion resistance of the alloy. The glue comprises epoxy resin and silane coupling agent.

The modularized inductor disclosed by the utility model is formed by splicing the inner layer module and the outer layer module instead of being integrally formed, materials adopted by the inner module and the outer module can be selected according to practical application, a rolling spraying-free process can be realized, the production cost can be reduced, the influence on the environment and the damage on the health of staff can be reduced, and meanwhile, the better product performance can be ensured.

The modularized inductor disclosed by the utility model can be prepared by adopting the following preparation method: firstly, mixing soft magnetic materials (powder particles such as carbonyl iron, amorphous iron or alloy) with glue, mechanically granulating to prepare granulated powder of mixed materials of soft magnetic powder and glue, and pressing the granulated powder into modules with various sizes by using a pressing machine; and winding the coil on one of the modules, assembling the coil and the modules in a stacking way, and performing secondary compression molding, wherein in the secondary compression process, the glue is extruded to the surface of the module, and the glue is heated at the same time to accelerate the solidification of the glue, so that the modules are bonded into a whole, and the modularized inductor is obtained.

The design of the module can be flexibly changed according to the design index of a user, for example, if a non-coating scheme is required to be used, iron-silicon-chromium alloy can be selected as the raw material of the external module, carbonyl iron powder is used as the raw material of the internal module, so that the shell of the modularized inductor has the rust-proof capability and can protect the internal module; if the scheme with the coating layer is needed, the outer module and the inner module can simultaneously adopt carboxyl iron powder as raw materials so as to achieve better performance. When the high-sense product is designed, the center pillar module (namely the inner module wound with the coil) and other inner modules with different performances can be used according to simulation conditions, so that the saturation conditions of all parts of the center pillar module are more uniform. If the technology is developed sufficiently, a new industry can be created to compact standard size module cores.

In one embodiment, the following method is used to prepare the modular inductor of the present utility model:

Firstly, preparing six inner modules of a cuboid with 15mm multiplied by 12mm multiplied by 5mm and one inner module of a cylinder with the diameter of 12mm and the height of 13mm by adopting a material mixed by carbonyl iron powder and glue by using the pressure of 1500MPa (or higher), and respectively preparing two outer modules with 57mm multiplied by 35mm multiplied by 2mm, 57mm multiplied by 15mm multiplied by 2mm and 35mm multiplied by 15mm multiplied by 2mm by adopting a material mixed by ferrosilicon-chromium alloy and glue by using the pressure of 6000MPa (or higher); then placing the inner module of the cylinder in the middle of the coil, and winding two coils of copper wires with the diameter of 18mm and the wire diameter of 4mm on the inner module of the cylinder; and placing six cuboid inner modules on two sides of the coil to form a stacked cuboid (namely an inductance inner structure) with the length and width of 55mm multiplied by 35mm multiplied by 15mm, and attaching the 6 outer modules on the outer layer of the stacked cuboid. And finally, pressing the assembly module inductor by using a press, heating and reshaping, and finally obtaining the product after hot pressing, namely the assembly module inductor. The most obvious characteristic of the product is that insulating layers formed by glue are arranged between different modules, and the insulating layers can separate induced current so as to achieve the effect of reducing eddy current loss.

The modularized inductor disclosed by the utility model has the following advantages:

(1) High density can be achieved: in the manufacturing process of the modularized inductor, the machine can be used for pressing all internal modules and external modules, when all the modules are pressed, very high pressure can be used for pressing iron powder to very high density, and then coils and all the modules can be pressed and formed by using lower pressure. If the iron powder and the coil are formed by hot pressing in the prior art, the copper wire is seriously deformed by applying excessive pressure, so that the resistance is increased, and the insulating layer of the copper wire is damaged, thereby causing the risk of short circuit; the structure of the utility model can avoid the problems in the prior art on the basis of achieving high density.

(2) The cost is saved: when the outer module is formed by pressing iron-silicon-chromium alloy materials, and the inner module is formed by pressing carboxyl iron powder, the outer coating paint spraying of the product is not needed, and the purpose of rust prevention can be achieved, so that the paint spraying material and labor cost can be saved, and the time of the whole process can be shortened.

(3) The eddy current loss is reduced: after the inductor is modularized, the gap between each module and the insulating layer can separate the induced current according to Faraday law in Maxwell's equationWhere E is the electric field strength, l is the loop length of the closed loop, t is time, B is the magnetic induction strength, and S is the area of the closed loop. The relation of induced electromotive force (voltage) and current is determined by ohm's law (electromotive force=current-impedance); when the impedance is unchanged (the materials are the same), the path length is reduced, which leads to a reduced magnetic flux change, and thus to a reduced induced electromotive force, and consequently to a corresponding reduced current. Thus, the effect of reducing the eddy current is achieved.

The background section of the present utility model may contain background information about the problem or environment of the present utility model rather than the prior art described by others. Accordingly, inclusion in the background section is not an admission of prior art by the applicant.

The foregoing is a further detailed description of the utility model in connection with specific/preferred embodiments, and it is not intended that the utility model be limited to such description. It will be apparent to those skilled in the art that several alternatives or modifications can be made to the described embodiments without departing from the spirit of the utility model, and these alternatives or modifications should be considered to be within the scope of the utility model. In the description of the present specification, reference to the terms "one embodiment," "some embodiments," "preferred embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the utility model. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction. Although embodiments of the present utility model and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the scope as defined by the appended claims.

Claims (10)

1. The utility model provides a modularization inductance, its characterized in that includes coil, a plurality of interior module and a plurality of outside module, interior module with outside module all contains soft magnetic material, the coil coiling is in one of them interior module, a plurality of interior module splices each other and forms inductance inner structure, and a plurality of outside module splices the outside of inductance inner structure is in order to with coil and a plurality of inside module parcel is in.

2. The modular inductor of claim 1, wherein insulation layers are provided between each of the inner modules, between each of the outer modules, and between the inner modules and the outer modules, respectively.

3. The modular inductor of claim 2, wherein the insulating layer is formed of glue.

4. The modular inductor of claim 1, wherein the inner module around which the coil is wound is of a cylindrical configuration, the other inner modules are of a cuboid or cubic configuration, and the outer modules are of a cuboid or cubic configuration.

5. The modular inductor as recited in claim 4, wherein the other inner modules are spliced to each other outside of the inner modules wound with the coil to form an inductor inner structure.

6. The modular inductor of claim 1, wherein the inner and outer modules are each a module molded from soft magnetic material.

7. The modular inductor of claim 1, wherein the modular inductor is a stamped configuration with a plurality of the outer modules surrounding the coil and the outer sides of a plurality of the inner modules.

8. The modular inductor of claim 7, wherein the inner and outer modules are each a module molded from a blend of soft magnetic material and glue.

9. A modular inductor according to claim 6 or 8, wherein the soft magnetic material used for compression molding the inner module is carboxyiron powder and the soft magnetic material used for compression molding the outer module is ferrosilicon-chromium alloy or carboxyiron powder.

10. A modular inductor according to claim 3 or 8, wherein the glue comprises an epoxy resin and a silane coupling agent.