WO2019010698A1 - 电抗器磁芯及其电抗器 - Google Patents

电抗器磁芯及其电抗器 Download PDF

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Publication number
WO2019010698A1
WO2019010698A1 PCT/CN2017/092980 CN2017092980W WO2019010698A1 WO 2019010698 A1 WO2019010698 A1 WO 2019010698A1 CN 2017092980 W CN2017092980 W CN 2017092980W WO 2019010698 A1 WO2019010698 A1 WO 2019010698A1
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WIPO (PCT)
Prior art keywords
yoke
reactor
lower yoke
upper yoke
center pillar
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PCT/CN2017/092980
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English (en)
French (fr)
Inventor
黄智�
褚江
端悦涛
姜桂林
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墨尚电子技术(上海)有限公司
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Priority to PCT/CN2017/092980 priority Critical patent/WO2019010698A1/zh
Priority to US16/622,686 priority patent/US11430597B2/en
Priority to CN201780090999.5A priority patent/CN110770860B/zh
Publication of WO2019010698A1 publication Critical patent/WO2019010698A1/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
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • 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
    • H01F27/28—Coils; Windings; Conductive connections
    • 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
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/38—Auxiliary core members; Auxiliary coils or windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F3/14—Constrictions; Gaps, e.g. air-gaps
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F2003/106—Magnetic circuits using combinations of different magnetic materials

Definitions

  • the invention relates to the technical field of reactors, in particular to a reactor core and a reactor thereof.
  • the patent document disclosed in the Patent Office of China Patent Office No. 102918610B uses a magnetic metal-containing resin package to make it compact, but the magnetic permeability of the magnetic resin is generally low, so the utilization of the yoke is improved. limited.
  • the mixed material design is adopted, the structure is very compact, and the efficiency is also high, but there are manufacturing problems, especially for larger sizes.
  • the patent document published by the Chinese Patent Office, No. 103714946B discloses a hybrid magnetic circuit magnetic integrated inductor that can maintain a high coupling effect and maximize the inductance of the coil auto-coupling, but there is a ferrite plate. The core is difficult to thin and has the risk of premature saturation.
  • the technical problem to be solved by the present invention is to provide a reactor core and a reactor thereof, which improves the utilization ratio of the yoke, has a compact structure, and is simple to manufacture.
  • the present invention provides a reactor core including a center pillar, an upper yoke, a lower yoke, and at least two high magnetic side pillars; the center pillar is disposed in an intermediate portion of the upper yoke Between the intermediate regions of the lower yoke, the center pillar is used to wind the coil, and the saturation magnetic flux density of the middle pillar is greater than the saturation magnetic flux density of the upper yoke and the lower yoke; the at least two The high magnetic side legs are spaced apart between the upper yoke and the lower yoke, and the two ends of each high magnetic side leg are respectively connected with the outer edge of the upper yoke and the outer edge of the lower yoke .
  • the two ends of the middle column are respectively inserted into the upper yoke and the lower yoke, and the insertion depth ratio d/D of each end of the middle column is greater than or equal to (B1- B2) / B1, where d is the insertion depth of the end of the middle column, D is the thickness of the upper yoke and the lower yoke, B1 is the saturation magnetic flux density of the middle column, and B2 is the saturation of the upper yoke and the lower yoke Magnetic flux density.
  • the two ends of the center pillar penetrate the upper yoke and the lower yoke, respectively.
  • the high magnetic side pillar has a magnetic permeability of not less than 200.
  • the material of the high magnetic edge pillar is a ferrite or an amorphous material.
  • each of the high magnetic side legs is symmetrically distributed around all of the center columns.
  • the center pillar is made of a metal powder core, and the upper yoke and the lower yoke are made of ferrite.
  • the metal powder core is a ferrosilicon or iron silicon material.
  • the center pillars are one or more, and the center pillars are spaced apart between the intermediate portion of the upper yoke and the intermediate portion of the lower yoke.
  • an air gap is provided on the center pillar.
  • the present invention also provides a reactor comprising a coil and the reactor core of any of the preceding embodiments, the coil being wound outside the center pillar.
  • the upper and lower ends of the coil are provided with an insulating end ring to isolate the coil from the center pillar and the coil and the upper yoke and the lower yoke.
  • a housing is further provided on the outside of the reactor core.
  • the outer casing is filled with a gel to connect the various parts of the reactor.
  • the present invention has the following beneficial effects compared with the prior art:
  • the material design using the saturation magnetic flux density of the middle column is larger than the saturation magnetic flux density of the upper yoke and the lower yoke, and the magnetic core or the yoke space of the reactor can be effectively utilized;
  • the dispersion magnetic field is formed by using at least two high magnetic permeability prisms. Two or more magnetic flux circuits can reduce the thickness of the yoke portion, make the structure compact, and easy to manufacture;
  • Inserting the middle column part into the upper yoke and the lower yoke can prevent the ferrite material in the yoke part from being saturated in advance.
  • FIG. 1 is a schematic structural view of a reactor with a center pillar and two high magnetic side pillars according to an embodiment of the present invention
  • FIG. 2 is a schematic view showing the depth of insertion of the upper yoke and the lower yoke of the center pillar according to an embodiment of the present invention
  • FIG. 3 is a schematic view showing the influence of the depth of the middle yoke inserted into the upper yoke and the lower yoke on the saturation characteristics according to an embodiment of the present invention
  • FIG. 4 is a schematic view showing an exploded structure of a reactor with a center pillar and a four-high magnetic edge column according to an embodiment of the present invention
  • FIG. 5 is a saturation curve diagram of a single-phase reactor according to an embodiment of the present invention.
  • FIG. 6 is a comparison diagram of core loss of a single-phase reactor and a ring-shaped FeSiAl reactor according to an embodiment of the present invention
  • FIG. 7 is a schematic structural view of a reactor with two center pillars and two high magnetic side pillars according to an embodiment of the present invention.
  • FIG. 8 is a schematic structural diagram of an application circuit of a reactor in an inverter circuit according to an embodiment of the present invention.
  • FIG. 9 is a schematic structural diagram of an application circuit of a reactor on a PFC line according to an embodiment of the present invention.
  • FIG. 10 is a schematic structural view of a reactor with three center pillars and three high magnetic side pillars according to an embodiment of the present invention.
  • the reactor core includes a center pillar 1, an upper yoke 2, a lower yoke 3, and at least two high magnetic side pillars 4.
  • the upper yoke 2 and the lower yoke 3 are equal, and the structural dimensions are the same, and can be exchanged with each other, and the shape is not limited.
  • the high magnetic edge column 4 can be understood to be made of a highly magnetic material. According to different design requirements, the high magnetic edge column 4 can be two, three, four, etc., and the shape is not limited, and can be a triangular column. Polygonal columns, cylinders, etc.
  • the center pillar 1 is disposed between the intermediate portion of the upper yoke 2 and the intermediate portion of the lower yoke 3. If it is a center pillar 1, the center pillar 1 is disposed between the middle position of the upper yoke 2 and the middle position of the lower yoke 3; if it is two or more center pillars 1, the area between all the middle pillars 1 corresponds to In the middle region of the upper yoke 2 and the intermediate portion of the lower yoke 3.
  • the center pillar 1 is used to wind the coil 5, and the saturation magnetic flux density of the center pillar 1 is greater than the saturation magnetic flux density of the upper yoke 2 and the lower yoke 3.
  • All of the high magnetic side pillars 4 are disposed between the upper yoke 2 and the lower yoke 3, and both ends of each of the high magnetic side pillars 4 are respectively outside the outer edge of the upper yoke 2 and the lower yoke 3. Connect along.
  • One of the high magnetic edge columns 4 The end is connected to the outer edge of the upper yoke 2, and the other end is connected to the outer edge of the lower yoke 3. Since the magnetic flux circuit is to be formed, it is preferably an aligned joint connection, which may be the end face and the upper side of the high magnetic side pillar 4.
  • the upper surface of the yoke 2 is flush, or the façade of the high magnetic side pillar 4 may be flush with the side surface of the upper yoke 3, and the same applies to the lower yoke 3.
  • the respective high magnetic conducting side columns 4 are relatively independently disposed between the upper yoke 2 and the lower yoke 3.
  • the material design of the saturation magnetic flux density of the middle pillar 1 is larger than the saturation magnetic flux density of the upper yoke 2 and the lower yoke 3, and the magnetic core or the reactor yoke space can be effectively utilized; at least two high magnetic side pillars are used. 4
  • the formation of two or more magnetic flux loops for dispersing the magnetic flux can reduce the thickness of the yoke portion, make the structure compact, and is easy to manufacture.
  • each of the high magnetic side pillars 4 is symmetrically distributed around all the center pillars 1 , in other words, each of the high magnetic flux side pillars 4 is opposite to the center pillar 1 itself (in the case where the center pillar 1 is one) or all The area surrounded by the center pillar 1 is symmetrically distributed, and the yoke magnetic flux can be more effectively dispersed, thereby reducing the thickness of the yoke.
  • the material of the upper yoke 2 and the lower yoke 3 of the embodiment of the present invention is ferrite, and the ferrite material has a relatively high magnetic permeability, which contributes to the magnetic flux in the yoke.
  • the iron partially diffuses and improves the utilization of the yoke.
  • the material of the center pillar 1 can be a metal powder core. It is well known that the saturation magnetic flux density of the metal powder core is larger than the saturation magnetic flux density of the ferrite, and the coil 5 is wound on the column 1 of the metal powder core. Lowering the winding radius of the coil 5 reduces DC resistance and cost.
  • the metal powder core may be a ferrosilicon or iron silicon material, of course, not limited thereto, and may also be other metal powder core materials.
  • the magnetic flux flows from the metal powder core column through the ferrite yoke to the other metal powder core column, so as to avoid the pre-saturation of the ferrite, the upper and lower irons
  • the thickness of the oxygen yoke will be very thick, making the size of the reactor very large and uneconomical; and the magnetic flux flows from one of the metal powder cores through the ferrite yoke directly to the other metal powder core column. It is not conducive to making full use of the yoke space, which will result in wasted space.
  • At least two high magnetic side pillars 4 are respectively connected from the outer edges of the upper and lower ferrite yokes to form a magnetic flux loop, which can avoid the column magnetic flux in the metal powder core in the ferrite yoke. Only on the iron A problem in which the yoke is too thick due to a fixed direction of diffusion.
  • the core loss of the ferrite material is much smaller than that of the metal powder core material. Therefore, the magnetic core is designed by the mixed material, which is a ring metal powder core solution or a square-shaped metal powder core block than the current industrial application. In the stacking scheme, the core loss is much lower.
  • the materials of the upper yoke 2, the lower yoke 3, and the center pillar 1 of the embodiment of the present invention are not limited to ferrites and metal powder cores, and other upper yokes 2 satisfying the saturation magnetic flux density of the center pillar 1 are larger.
  • the corresponding material of the saturation magnetic flux density of the lower yoke 3 is also applicable, which can help to reduce the winding radius of the coil 5, reduce the DC resistance and cost, and realize the shunt magnetic flux loop by providing the high magnetic conducting side column 4, thereby avoiding The middle column 1 magnetic flux spreads only in a certain fixed direction on a yoke, causing the yoke to be too thick.
  • the magnetic permeability of the high magnetic conducting side pillar 4 is not less than 200, which can guide the yoke magnetic flux relatively effectively, shield the magnetic flux from leaking, and can reduce the coupling and facilitate the multi-column 1 solution.
  • the windings work independently.
  • the material of the high magnetic side pillar 4 may be ferrite or amorphous material, of course, but not limited thereto, and other high magnetic permeability materials.
  • the two ends of the middle column 1 are respectively inserted into the upper yoke 2 and the lower yoke 3, in order to avoid premature saturation of the ac contact surface of the center pillar 1 and the upper yoke 2,
  • the magnetic flux passing through the ab torus should be less than or equal to the B2/B1 times of the total magnetic flux, that is, (Dd)/D ⁇ B2/B1, so the insertion depth ratio d/D of each end of the middle column 1 is greater than or equal to (B1- B2)/B1, where d is the insertion depth of the end of the center pillar 1, D is the thickness of the upper yoke 2, the lower yoke 3, B1 is the saturation magnetic flux density of the center pillar 1, and B2 is the upper yoke iron 2.
  • the following yoke iron 2, the lower yoke iron 3 is a ferrite material, and the center pillar 1 is a metal powder core material as an example.
  • the purpose of inserting the middle pillar 1 into the yoke and setting the corresponding insertion depth ratio is described. Of course, the same is true for other materials.
  • the saturation magnetic flux density of the ferrite material is lower than the saturation magnetic flux density of the metal powder core, as shown in Fig. 2, the upper yoke of the metal pillar core material and the ferrite material.
  • the contact ac surface of the iron 2 is prone to local saturation of the ferrite material, and the same applies to the lower yoke 3.
  • the saturation magnetic flux density of the metal powder core is about 5/4 of the saturation magnetic flux density of the ferrite.
  • the magnetic flux passing through the ab ring surface should be less than or equal to the total magnetic flux.
  • a through hole is formed in the upper yoke 2 and the lower yoke 3, and the through holes are formed at both ends of the center pillar 1 to ensure that the upper yoke 2 and the lower yoke 3 do not prematurely saturate. It is easier to implement. In other words, both ends of the center pillar 1 penetrate the upper yoke 2 and the lower yoke 3, respectively.
  • the center pillars 1 may be one or two or more, and each of the center pillars 1 is spaced apart between the intermediate portion of the upper yoke 2 and the intermediate portion of the lower yoke 3.
  • the area surrounded by each of the center pillars 1 is an intermediate portion corresponding to the upper yoke 2 and the lower yoke 3.
  • the air column 11 is disposed on the center pillar 1 to enhance the anti-saturation capability of the reactor.
  • the reactor core of the foregoing embodiment is used in a reactor, the reactor comprising a coil 5 and a reactor core according to any of the preceding embodiments,
  • the coil 5 is wound outside the center pillar 1.
  • the coil 5 is wound on the center pillar 1, and is sandwiched by the upper yoke 2 and the lower yoke 3.
  • the depth d of the upper yoke 2 and the lower yoke 3 at both ends of the center pillar 1 is, for example, a yoke.
  • FIG. 4 it is an exploded view of the product structure of a reactor.
  • the coil 5 is wound on the center pillar 1, and is sandwiched by the upper yoke 2 and the lower yoke 3.
  • Four independent high-conductivity side pillars 4 are symmetrically disposed around the center pillar 1 to disperse the upper yoke 2 and the lower yoke.
  • the middle column 1 is completely inserted into the upper yoke 2, the lower yoke 3 and the insertion position is located in the middle region of the upper yoke 2, the lower yoke 3; the four independent high magnetic edge columns 4 from the upper yoke 2
  • the outer edge of the lower yoke 3 is connected to form a magnetic flux circuit, and the magnetic flux of the yoke is dispersed to make the yoke thin.
  • the center pillar 1 is made of a ferrosilicon metal powder core.
  • two air gaps 11 are also disposed on the center pillar 1, and of course, the number of air gaps 11 is not limited; the upper yoke iron 2
  • the material of the lower yoke 3 and the four independent high magnetic side pillars 4 may be MnZn ferrite, and its magnetic permeability is 2,300.
  • the upper and lower ends of the coil 5 are provided with an insulating end ring 6 for isolating the coil 5 and the center pillar 1 and the coil 5 from the upper yoke 2 and the lower yoke 3.
  • the coil 5 and the center pillar 1 and the upper yoke 2 and the lower yoke 3 are isolated using the upper and lower insulating end rings 6.
  • the reactor may further include a casing disposed outside the reactor core.
  • the outer casing includes a casing cover 72 and a casing main body 71 which are connected to each other to form a closed space in which the upper yoke 2, the lower yoke 3 and the four independent high magnetic side columns 4 are fixed.
  • the reactor in other embodiments can also be provided with a casing.
  • the outer casing is filled with a colloid so that the various parts of the reactor are integrated.
  • a wire slot can be formed in one of the side walls of the outer casing, and then the outer casing is filled with glue to integrate the reactor to enhance the heat conductivity and achieve the effect of suppressing working noise.
  • FIG. 5 is a graph showing the saturation curve of the reactor of the present embodiment. It is shown by the DC bias of the reactor. It can be seen that the saturation curve of this embodiment is very smooth, indicating that the yoke is not saturated in advance.
  • FIG. 6 is a comparison of the core loss of the reactor of the present embodiment and the annular iron-silicon-aluminum reactor of the same size and approximate size, and the reactor of the embodiment has obvious advantages in core loss.
  • Multiple coils may be used in practice.
  • a two-column single-phase reactor to increase the anti-saturation capability of the reactor; for example, two-phase or three-phase reactors need to be integrated to reduce costs.
  • a two-column single phase reactor In yet another embodiment, referring to Figure 7, a two-column single phase reactor.
  • the two coils 5 on the two center pillars 1 are connected in series to form one winding, the winding input terminal receives the current Iin, the center pillar 1 is inserted into the upper yoke iron 2, the lower yoke iron 3 is 1/2 of the depth, and the insertion position is located on the upper yoke iron 2.
  • the middle portion of the lower yoke 3; a total of six air gaps 11 are also disposed on the center pillar 1.
  • the two independent high magnetic side pillars 4 are connected to the upper yoke 2 and the lower yoke 3 from the outer edge, and the materials of the two independent high magnetic side pillars 4 are amorphous. Compared with a reactor with only one column, the reactor doubles the stored energy and can better adapt to the needs of high current design.
  • the utility model of the reactor with a middle column 1 and two coils 5 is used in the inverter circuit, and the upper yoke, the lower yoke and the two high magnetic side pillars can be integrated.
  • the structure and the high magnetic side pillar are made of ferrite.
  • the two U-shaped integral structures 8 are used to connect the upper yoke, the lower yoke and the two high magnetic side pillars to complete the magnetic circuit closure.
  • the middle column 1 is still made of metal powder core material, the metal powder core material is iron silicon, and the middle column 1 is completely inserted into the upper yoke and the lower yoke corresponding to the integral structure 8, and the insertion position is located on the upper yoke and the lower yoke.
  • FIG. 9 the application of a reactor in a solar inverter interleaved PFC (Power Factor Correction) line is illustrated in the embodiment of the present invention.
  • the two coils 5 are respectively placed on the two center pillars 1.
  • the center pillar 1 is made of iron-silicon aluminum, and the center pillar 1 is inserted into the upper yoke 2 and the lower yoke 3 to a depth exceeding 1/4, and the insertion position is located.
  • the high magnetic edge column 4 is made of amorphous lamination, and its magnetic permeability is greater than 5000; the magnetic permeability of the upper yoke 2, the lower yoke 3 and the two high magnetic side pillars 4 are compared. High, the two-phase PFC reactors have a small coupling coefficient with each other and can operate independently of each other.
  • a three-phase reactor according to an embodiment of the present invention can be used in a larger power inverter LC output filter network or an LCL output filter network.
  • the three-phase reactor of the present embodiment is compact in structure, can achieve large power output and small core loss at the same time; and because the three-phase reactors are integrated with each other, the cost can be effectively reduced.

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Abstract

一种电抗器磁芯及其电抗器，该电抗器磁芯包括中柱（1）、上轭铁（2）、下轭铁（3）及至少两个高导磁边柱（4）；所述中柱（1）设置在所述上轭铁（2）的中间区域、下轭铁（3）的中间区域之间，所述中柱（1）外用以绕制线圈（5），且所述中柱（1）的饱和磁通密度大于所述上轭铁（2）、下轭铁（3）的饱和磁通密度；所述至少两个高导磁边柱（4）间隔设置在所述上轭铁（2）、下轭铁（3）之间，且每个高导磁边柱（4）的两端分别与所述上轭铁（2）的外沿、下轭铁（3）的外沿连接。该电抗器磁芯及其电抗器，提升了轭铁利用率，结构紧凑，同时制造简单。

Description

电抗器磁芯及其电抗器 技术领域
本发明涉及电抗器技术领域，尤其涉及的是一种电抗器磁芯及其电抗器。
背景技术
随着新能源技术和电动汽车的发展，各种电抗器需求如光伏逆变器电路的升压电抗器，逆变器输出电抗器以及电动汽车主动力电池升压电抗器等变得旺盛。由于功率半导体器件的开关频率不断提高，传统的硅钢片电抗器因为损耗较大已经变得不太适用，取而代之的是以铁硅和铁硅铝材质为代表的金属粉芯电抗器。这种电抗器目前有两种方式，一种是采用环形电抗器方案，此方案存在着绕线困难，不利于规模化生产的问题；另外一种是采用块状金属粉芯堆叠为口型，将线圈绕组绕制在上下轭铁夹持的中柱上，此种方案存在着上下轭铁的空间利用率不足、尺寸较大的问题。
中国专利局公开的公告号为102918610B的专利文件中，为解决此问题，采用含磁性金属树脂封装，使之结构紧凑，但是由于磁性树脂的导磁率一般较低，因而对轭铁利用率的提升有限。中国专利局公开的公告号为102074333B的专利文件中，采用混合材料设计，结构非常紧凑，且效率也很高，但是存在着制造问题，尤其是对较大尺寸比较困难。中国专利局公开的公告号为103714946B的专利文件，揭露了一种混合磁路磁集成电感器，可保持高的耦合效果，又能够最大限度提升线圈自耦的电感量，但是存在铁氧体平板磁芯很难薄型化且有提前饱和风险的问题。
发明内容
本发明所要解决的技术问题是提供一种电抗器磁芯及其电抗器，提升轭铁利用率，结构紧凑，同时制造简单。
为解决上述问题，本发明提出一种电抗器磁芯，包括中柱、上轭铁、下轭铁及至少两个高导磁边柱；所述中柱设置在所述上轭铁的中间区域、下轭铁的中间区域之间，所述中柱外用以绕制线圈，且所述中柱的饱和磁通密度大于所述上轭铁、下轭铁的饱和磁通密度；所述至少两个高导磁边柱间隔设置在所述上轭铁、下轭铁之间，且每个高导磁边柱的两端分别与所述上轭铁的外沿、下轭铁的外沿连接。
根据本发明的一个实施例，所述中柱的两端分别插入至所述上轭铁、下轭铁中，所述中柱的两端各自的插入深度比例d/D为大于等于(B1-B2)/B1，其中，d为中柱端部的插入深度，D为上轭铁、下轭铁的厚度，B1为中柱的饱和磁通密度，B2为上轭铁、下轭铁的饱和磁通密度。
根据本发明的一个实施例，所述中柱的两端分别穿透所述上轭铁、下轭铁。
根据本发明的一个实施例，所述高导磁边柱的导磁率不小于200。
根据本发明的一个实施例，高导磁边柱的材料为铁氧体或非晶材料。
根据本发明的一个实施例，各高导磁边柱在全部中柱的周围呈对称分布。
根据本发明的一个实施例，所述中柱的材质为金属粉芯，所述上轭铁、下轭铁的材质为铁氧体。
根据本发明的一个实施例，所述金属粉芯为铁硅铝或铁硅材料。
根据本发明的一个实施例，所述中柱为一个或两个以上，各中柱间隔设置在所述上轭铁的中间区域、下轭铁的中间区域之间。
根据本发明的一个实施例，所述中柱上设置有气隙。
本发明还提供一种电抗器，包括线圈及如前述实施例中任意一项所述的电抗器磁芯，所述线圈绕制在中柱外。
根据本发明的一个实施例，所述线圈的上下两端设置有绝缘端圈，以隔离线圈与所述中柱及线圈与所述上轭铁、下轭铁。
根据本发明的一个实施例，还包括一外壳，设置在所述电抗器磁芯的外侧。
根据本发明的一个实施例，所述外壳内灌有胶体，以使电抗器各部分连成一体。
采用上述技术方案后，本发明相比现有技术具有以下有益效果：
采用中柱的饱和磁通密度大于上轭铁、下轭铁的饱和磁通密度的材料设计，能有效利用磁芯或者说电抗器轭部空间；采用至少两个高导磁边柱形成分散磁通的两个以上磁通回路，可以减小轭铁部分厚度，使结构紧凑，而且容易制造；
将中柱部分插入上轭铁、下轭铁，可以避免轭铁部分铁氧体材质提前饱和。
附图说明
图1为本发明一实施例的带一中柱和两高导磁边柱的电抗器结构示意图；
图2为本发明一实施例的中柱插入上轭铁、下轭铁的深度示意图；
图3为本发明一实施例的中柱插入上轭铁、下轭铁的深度对饱和特性的影响示意图；
图4为本发明一实施例的带一中柱和四高导磁边柱的电抗器爆炸结构示意图；
图5为本发明一实施例的单相电抗器的饱和曲线图；
图6为本发明一实施例的单相电抗器与环形FeSiAl电抗器的铁芯损耗对比图；
图7为本发明一实施例的带两中柱和两高导磁边柱的电抗器结构示意图；
图8为本发明一实施例的电抗器在逆变电路中的应用电路结构示意图；
图9为本发明一实施例的电抗器在PFC线路上的应用电路结构示意图；
图10为本发明一实施例的带三中柱和三高导磁边柱的电抗器结构示意 图。
图中标记说明：
1-中柱，11-气隙，2-上轭铁，3-下轭铁，4-高导磁边柱，5-线圈，6-绝缘端圈，71-外壳主体，72-外壳盖板，8-一体结构。
具体实施方式
为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图对本发明的具体实施方式做详细的说明。
在下面的描述中阐述了很多具体细节以便于充分理解本发明。但是本发明能够以很多不同于在此描述的其它方式来实施，本领域技术人员可以在不违背本发明内涵的情况下做类似推广，因此本发明不受下面公开的具体实施的限制。
在一个实施例中，参看图1，电抗器磁芯包括中柱1、上轭铁2、下轭铁3及至少两个高导磁边柱4。当然，若在中柱1外绕制线圈5，即可成为一电抗器。上轭铁2、下轭铁3两者是对等的，结构尺寸均相同，可相互调换，形状不限。高导磁边柱4可以理解，是由高导磁材料制成，根据不同的设计需要，高导磁边柱4可以为两个、三个、四个等，形状不限，可以是三角柱、多边形柱、圆柱等。
中柱1设置在上轭铁2的中间区域、下轭铁3的中间区域之间。如果是一个中柱1，该中柱1设置在上轭铁2的中间位置、下轭铁3的中间位置之间；如果是两个以上中柱1，则全部中柱1之间的区域对应于上轭铁2的中间区域、下轭铁3的中间区域。中柱1外用以绕制线圈5，且中柱1的饱和磁通密度大于上轭铁2、下轭铁3的饱和磁通密度。
全部高导磁边柱4间隔设置在上轭铁2、下轭铁3之间，且每个高导磁边柱4的两端分别与上轭铁2的外沿、下轭铁3的外沿连接。高导磁边柱4的一 端与上轭铁2的外沿连接，另一端与下轭铁3的外沿连接，由于要形成磁通回路，因而优选是对齐式接合连接，可以是高导磁边柱4的端面与上轭铁2的上表面平齐、或者可以是高导磁边柱4的立面与上轭铁3的侧面平齐，与下轭铁3之间也是同理。各个高导磁边柱4之间是相对独立设置在上轭铁2、下轭铁3之间的。
采用中柱1的饱和磁通密度大于上轭铁2、下轭铁3的饱和磁通密度的材料设计，能有效利用磁芯或者说电抗器轭部空间；采用至少两个高导磁边柱4形成分散磁通的两个以上磁通回路，可以减小轭铁部分厚度，使结构紧凑，而且容易制造。
比较好的是，各高导磁边柱4在全部中柱1的周围呈对称分布，换言之，各高导磁边柱4相对中柱1本身(在中柱1为一个的情况下)或全部中柱1围成的区域对称分布，可更有效地分散轭铁磁通，从而减小轭铁厚度。
优选的，为有效利用轭部空间，本发明实施例的上轭铁2、下轭铁3的材质采用为铁氧体，铁氧体材质的导磁率一般比较高，有助于磁通在轭铁部分扩散，提高轭铁利用率。同时，中柱1的材质可以为金属粉芯，众所周知，金属粉芯的饱和磁通密度比铁氧体的饱和磁通密度更大，线圈5绕制在金属粉芯中柱1上有助于降低线圈5的绕线半径，降低直流电阻和成本。
金属粉芯可以为铁硅铝或铁硅材料，当然不限于此，也可以是其他金属粉芯材料。
如果采用传统口字磁芯结构的两柱式电抗器，磁通从金属粉芯中柱经过铁氧体轭铁流向另外一金属粉芯中柱，那么为避免铁氧体的提前饱和，上下铁氧体轭铁的厚度将会很厚，使得电抗器的尺寸变得非常庞大和不经济；而且磁通从其中一金属粉芯中柱经过铁氧体轭铁直接流向另外一金属粉芯中柱，并不利于充分利用轭部空间，会造成空间浪费。
而本发明实施例采用了至少两高导磁边柱4分别从上、下两铁氧体轭铁外沿将其衔接构成磁通回路，可以避免金属粉芯中柱磁通在铁氧体轭铁上只向某 一固定方向扩散而造成的轭铁太厚的问题。
同等情况下，铁氧体材质的铁芯损耗比金属粉芯材质的铁芯损耗要小很多，所以通过混合材料设计磁芯，比目前工业应用的环形金属粉芯方案或者口字形金属粉芯块堆叠方案，铁芯损耗要低很多。
当然，本发明实施例的上轭铁2、下轭铁3及中柱1材料也并不限于铁氧体、金属粉芯，其他满足中柱1的饱和磁通密度大于的上轭铁2、下轭铁3的饱和磁通密度的对应材料也同样适用，可以有助于降低线圈5的绕线半径，降低直流电阻和成本，以及通过设置高导磁边柱4实现分流磁通回路，避免中柱1磁通在一轭铁上只向某一固定方向扩散，造成轭铁太厚的问题。
优选的，高导磁边柱4的导磁率不小于200，能比较有效地引导轭铁磁通，屏蔽磁通外泄，且对于多中柱1的方案来说，可以减小耦合、便于多绕组独立工作。
优选的，高导磁边柱4的材料可以为铁氧体或非晶材料，当然不限于此，也可以是其他高导磁材料。
在一个实施例中，参看图1和图2，中柱1的两端分别插入至上轭铁2、下轭铁3中，为避免中柱1与上轭铁2的ac接触面提前饱和，从ab环面经过的磁通量应小于等于总磁通的B2/B1倍，即(D-d)/D≤B2/B1，所以中柱1的两端各自的插入深度比例d/D为大于等于(B1-B2)/B1，其中，d为中柱1端部的插入深度，D为上轭铁2、下轭铁3的厚度，B1为中柱1的饱和磁通密度，B2为上轭铁2、下轭铁3的饱和磁通密度。
下面以上轭铁2、下轭铁3为铁氧体材质及中柱1为金属粉芯材质为例，结合图2和图3，来描述中柱1插入轭铁及设置相应插入深度比例的目的，当然对于其他材质的情况也是同理。
如前所述，铁氧体材质的饱和磁通密度比金属粉芯的饱和磁通密度要低，那么如图2所示，在金属粉芯材质的中柱1和铁氧体材质的上轭铁2的接触位置ac面很容易出现铁氧体材质的局部饱和，对于下轭铁3来说也是同理。一 般来讲，金属粉芯的饱和磁通密度约为铁氧体的饱和磁通密度的5/4以上，为避免ac面提前饱和，从ab环面经过的磁通量应小于等于总磁通的4/5，那么(D-d)/D≤4/5，则有d/D≥1/5，即金属粉芯中柱插入铁氧体轭铁的深度至少为铁氧体轭铁厚度的1/5以上。
同时，可以从图2中看出，金属粉芯中柱两端插入上、下两铁氧体轭铁内，其插入位置应位于铁氧体轭铁的中间区域，这样金属粉芯中柱内的磁通才会四散进入铁氧体轭铁，而不是只往某一方向流动，有助于降低铁氧体轭铁的总体厚度。
如图3所示，当金属粉芯中柱完全不插入铁氧体轭铁或者插入铁氧体轭铁深度小于轭铁厚度的1/5(d/D＝0，16.7％)时，电抗器的饱和电流曲线在后段有突然下降，电流ldc在8A之后饱和度L/L0突然下降，对应用上会有重载时纹波过大，或者严重时影响线路输出稳定的情况；而插入深度在铁氧体轭铁厚度的1/5及以上(d/D＝25.0％，33.3％，50.0％，100％)时，可以看到饱和电流曲线非常平滑，抗饱和能力大大加强。
优选的是，可在上轭铁2、下轭铁3开设通孔，中柱1的两端部撑满通孔，既可保证上轭铁2、下轭铁3不会出现提前饱和，也较易实施。换言之，中柱1的两端分别穿透上轭铁2、下轭铁3。
中柱1可以为一个或两个以上，各中柱1间隔设置在上轭铁2的中间区域、下轭铁3的中间区域之间。各中柱1围成的区域为上轭铁2、下轭铁3对应的中间区域。
优选的，中柱1上设置有气隙11，可以增强电抗器的抗饱和能力。
在一个实施例中，参看图1，将前述实施例中的电抗器磁芯用在电抗器中，电抗器包括线圈5及如前述实施例中任意一项所述的电抗器磁芯，所述线圈5绕制在中柱1外。
具体的，图1中，中柱1上缠绕线圈5，且被上轭铁2、下轭铁3夹持，中柱1两端插入上轭铁2、下轭铁3的深度d例如为轭铁厚度D的1/2，以防 止上轭铁2、下轭铁3提前饱和；且中柱1插入上轭铁2、下轭铁3的位置位于其中间区域；两独立高导磁边柱4从上轭铁2、下轭铁3外沿将其衔接构成磁通回路，分散轭铁磁通流向，使轭铁薄型化。
在另一实施例中，如图4所示，为一电抗器的产品结构爆炸图。中柱1上缠绕线圈5，且被上轭铁2、下轭铁3夹持，在中柱1周围对称设置了四个独立高导磁边柱4，以分散上轭铁2、下轭铁3的磁通流向；中柱1完全插入上轭铁2、下轭铁3且插入位置位于上轭铁2、下轭铁3的中间区域；四独立高导磁边柱4从上轭铁2、下轭铁3外沿将其衔接构成磁通回路，分散轭铁磁通流向，使轭铁薄型化。其他相同之处也可以参看前述实施例的描述内容。
优选的，中柱1材质为铁硅铝金属粉芯，为增强电抗器的抗饱和能力，在中柱1上还设置有两气隙11，当然气隙11数量不限；上轭铁2、下轭铁3和四独立高导磁边柱4材质可以为MnZn铁氧体，其导磁率为2300。
优选的，线圈5的上下两端设置有绝缘端圈6，以隔离线圈5与中柱1及线圈5与上轭铁2、下轭铁3。继续参看图4，使用上下两个绝缘端圈6隔离线圈5和中柱1以及上轭铁2、下轭铁3。
优选的，电抗器还可以包括一外壳，设置在电抗器磁芯的外侧。在图4中，外壳包括外壳盖板72与外壳主体71，相互连接可以形成一封闭空间，固定了上轭铁2、下轭铁3和四个独立高导磁边柱4。当然，其他实施例中的电抗器同样也可以设置一外壳。
进一步的，外壳内灌有胶体，以使电抗器各部分连成一体。可以在外壳的其中一侧壁开设出线槽，然后通过该出线槽向外壳内灌胶，使电抗器一体化以增强其导热能力并达到抑制工作噪音的效果。
图5是本实施例的电抗器饱和曲线，通过电抗器直流偏置情况来表示，可以看到本实施例的饱和曲线非常平滑，说明轭铁并没有提前饱和。图6是本实施例的电抗器与同一规格近似尺寸的环形铁硅铝电抗器的铁芯损耗对比情况，本实施例的电抗器在铁芯损耗方面有着明显的优势。
实际应用时，可能会用到多个线圈。比如两柱式单相电抗器以增加电抗器的抗饱和能力；比如两相或者三相的电抗器，需要集成在一起以减小成本。基于本发明实施例内容，还能扩展为多个线圈的集成方案，减小体积的同时可满足不同场合的单相和多相电抗器需求。
在又一个实施例中，参看图7，为两柱式单相电抗器。两中柱1上的两线圈5相互串联构成一个绕组，绕组输入端接收电流Iin，中柱1插入至上轭铁2、下轭铁3深度的1/2，且插入位置位于上轭铁2、下轭铁3的中间区域；中柱1上还共设置有六个气隙11。两独立高导磁边柱4从外沿连接上轭铁2、下轭铁3，两独立高导磁边柱4的材质为非晶。该电抗器与只有一柱的电抗器相比，储能量增大一倍，可以更好的适应大电流设计的需求。
在又一个实施例中，参看图8，为带一中柱1和两线圈5结构的电抗器在逆变电路中的应用，上轭铁、下轭铁和两高导磁边柱可以为一体结构，高导磁边柱材质为铁氧体，在实施例中，用两个U型的一体结构8对接成为整体的上轭铁、下轭铁和两高导磁边柱，完成磁路闭合，中柱1仍采用金属粉芯材质，金属粉芯材质为铁硅，并将中柱1完全插入一体结构8对应的上轭铁、下轭铁中，且插入位置位于上轭铁、下轭铁的中间区域；中柱1上放置两个分立线圈5，构成两个绕组，用作逆变器输出端电抗器，输入电压为Vbus，输出电压为Vo；此结构有助于减小电抗器体积，并且由于L线、N线上的电抗器相互对称，有利于抑制共模噪音。
在又一个实施例中，参看图9，为本发明实施例电抗器在太阳能逆变器交错式PFC(Power Factor Correction，功率因数校正)线路上的应用。图9中，两线圈5分别套在两中柱1上，中柱1的材质为铁硅铝，中柱1插入至上轭铁2、下轭铁3的深度超过1/4，且插入位置位于上轭铁2、下轭铁3的中间区域；左右两高导磁边柱4连接上轭铁2、下轭铁3；两线圈5构成两个绕组绕制在两中柱1上，用作单独的两相PFC电抗器。高导磁边柱4材质为非晶叠片，其导磁率大于5000；由于上轭铁2、下轭铁3及两高导磁边柱4的导磁率比较 高，该两相PFC电抗器相互之间的耦合系数很小，相互之间可以单独运行。
在又一个实施例中，参看图10，为本发明实施例的三相电抗器，可用在较大功率的逆变器LC输出滤波网络或者LCL输出滤波网络。本实施例中，有三个中柱1，且每一中柱1上均有一对应的立绕线圈5绕组；所有中柱1及线圈4均被上轭铁2、下轭铁3夹持，而且三中柱1均完全插入上轭铁2、下轭铁3中，其插入位置位于上轭铁2、下轭铁3的中间区域。在上轭铁2、下轭铁3的外沿有三个独立高导磁边柱4，连接上轭铁2、下轭铁3与其衔接构成磁通回路，中柱1的材质为铁硅铝金属粉芯，上轭铁2、下轭铁3和三各个独立高导磁边柱4材质为MnZn铁氧体。本实施例的三相电抗器结构紧凑，可同时实现较大功率输出和较小的铁芯损耗；并且由于三相电抗器相互集成，可有效降低成本。
本发明虽然以较佳实施例公开如上，但其并不是用来限定权利要求，任何本领域技术人员在不脱离本发明的精神和范围内，都可以做出可能的变动和修改，因此本发明的保护范围应当以本发明权利要求所界定的范围为准。

Claims (14)

  1. 一种电抗器磁芯，其特征在于，包括中柱、上轭铁、下轭铁及至少两个高导磁边柱；所述中柱设置在所述上轭铁的中间区域、下轭铁的中间区域之间，所述中柱外用以绕制线圈，且所述中柱的饱和磁通密度大于所述上轭铁、下轭铁的饱和磁通密度；所述至少两个高导磁边柱间隔设置在所述上轭铁、下轭铁之间，且每个高导磁边柱的两端分别与所述上轭铁的外沿、下轭铁的外沿连接。
  2. 如权利要求1所述的电抗器磁芯，其特征在于，所述中柱的两端分别插入至所述上轭铁、下轭铁中，所述中柱的两端各自的插入深度比例d/D为大于等于(B1-B2)/B1，其中，d为中柱端部的插入深度，D为上轭铁、下轭铁的厚度，B1为中柱的饱和磁通密度，B2为上轭铁、下轭铁的饱和磁通密度。
  3. 如权利要求2所述的电抗器磁芯，其特征在于，所述中柱的两端分别穿透所述上轭铁、下轭铁。
  4. 如权利要求1所述的电抗器磁芯，其特征在于，所述高导磁边柱的导磁率不小于200。
  5. 如权利要求1所述的电抗器磁芯，其特征在于，高导磁边柱的材料为铁氧体或非晶材料。
  6. 如权利要求1所述的电抗器磁芯，其特征在于，各高导磁边柱在全部中柱的周围呈对称分布。
  7. 如权利要求1所述的电抗器磁芯，其特征在于，所述中柱的材质为金属粉芯，所述上轭铁、下轭铁的材质为铁氧体。
  8. 如权利要求7所述的电抗器磁芯，其特征在于，所述金属粉芯为铁硅铝或铁硅材料。
  9. 如权利要求1所述的电抗器磁芯，其特征在于，所述中柱为一个或两个以上，各中柱间隔设置在所述上轭铁的中间区域、下轭铁的中间区域之间。
  10. 如权利要求1所述的电抗器磁芯，其特征在于，所述中柱上设置有气隙。
  11. 一种电抗器，其特征在于，包括线圈及如权利要求1-10中任意一项所述的电抗器磁芯，所述线圈绕制在中柱外。
  12. 如权利要求11所述的电抗器，其特征在于，所述线圈的上下两端设置有绝缘端圈，以隔离线圈与所述中柱及线圈与所述上轭铁、下轭铁。
  13. 如权利要求11所述的电抗器，其特征在于，还包括一外壳，设置在所述电抗器磁芯的外侧。
  14. 如权利要求13所述的电抗器，其特征在于，所述外壳内灌有胶体，以使电抗器各部分连成一体。
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