WO2019200897A1

WO2019200897A1 - Flat-wire vertical winding inductance coil and vertical winding inductor

Info

Publication number: WO2019200897A1
Application number: PCT/CN2018/114573
Authority: WO
Inventors: 邵革良; 管春杨
Original assignee: 深圳市伊戈尔沐磁科技有限公司; 伊戈尔电气股份有限公司
Priority date: 2018-04-17
Filing date: 2018-11-08
Publication date: 2019-10-24
Also published as: CN108305743A

Abstract

A flat-wire vertical winding inductance coil formed by vertically winding a plurality of flat wires. Chamfers are provided on the inner side of the flat wire, and the sum of the areas of the chamfers is 3-10% of the original cross sectional area of the flat wire. According to the present invention, one side of the flat wire is chamfered, then the thin side is made to face inwards, and a winding and bending jig abuts against the thin side of the flat wire to perform inward bending and winding, thereby ensuring that the thickness of the deformed inner side part of the vertical winding flat wire after R-angle bending would not exceed the thickness t of the wire, such that a vertical winding inductance coil meeting the condition of L=n×t can be obtained. In addition, the cross sectional area of a copper wire of the coil would not obviously decrease, so that the coil is maintained to be approximate to the wire carrier density of a conventional vertical winding wire.

Description

Flat wire vertical winding inductor and vertical winding inductor

Technical field

[0001] The present invention relates to the field of electrical components, and more particularly to a flat wire wound inductor and a vertical wound inductor.

Background technique

[0002] Power inductors with flat wire windings have been widely used in various high frequency and high power switching power supplies such as photovoltaic inverters, UPS, and DC charging makeup modules in recent years. The vertical winding of the flat wire is a rectangular wire whose cross-sectional shape is much larger than the thickness of the wire. As shown in Fig. 1, the normal direction of the width of the wire is bent along the side of the thickness of the wire. Winding, the purpose of achieving more turns in the overall length of a particular coil.

[0003] With the high efficiency, high power density, and high integration of various high-frequency and high-power power sources described above, the overall space size of the power supply is extremely compressed, and in the circuits of these power products, it is essential. The size of the power magnetic components occupies the most significant size space of the power supply volume. The reduction in the size of these power inductor components has become one of the most important design goals of power supply products, and therefore, maintaining the same electrical performance specifications. In the case, how to further reduce the volume of the vertical winding power inductor, reduce the power loss of the inductor, and further reduce the cost of the vertical winding power inductor is the object of the present invention.

[0004] The upper part of FIG. 2 is a common square vertical winding inductor coil, which is formed by a plurality of 弹簧 spring-type flat wires, the total length L of the coil, the thickness of the flat wire is t, and the width of the flat wire is w. Where the width w is several to several tens of times the thickness t of the flat line. In order to form a flat wire with a width-to-thickness ratio w/t in the direction shown in the figure, it is necessary to fasten the winding jig of the vertical winding machine with a certain rounded corner to the inner side of the flat wire, and fold the flat wire along the inner side. Bending forming. Since the flat wire is bent laterally, the inner side wall of the flat wire will be subjected to a large bending stress, and the thickness t of the flat wire is thin, and the bending stress per unit area is very large, and the result of the bending is like As shown in Fig. 2, the flat line inside the corner is flattened to form an R-angle pit. At this time, the thickness of the inner side of the copper wire is squeezed and thickened. According to the width-thickness ratio of the flat line, the flat line of the aspect ratio is larger. The ratio d/t of the inner thickness to the thickness t before the flat line is more than 1 is larger. At the same time, since the bending stroke outside the flat line bending is much larger than the average bending stroke of the flat line, the outer flat line of the bending angle is caused. Stretched Thinning, this is why the flat wire coil has a large gap on the outside of the coil and a thick inside. For flat wires with a common width-to-thickness ratio w/t of more than 3 times, especially after a small R-angle bend, d _> :>t, so that the minimum total length of the coil L=nxd»nxt (n is the number of turns of the coil), so the more The small bending radius, that is, the smaller the bending R angle of the vertical winding inductor, the longer the total minimum length L of the same number of coils becomes, so that the length dimension of the inductor is not effectively controlled.

Summary of invention

technical problem

Problem solution

Technical solution

The present invention is directed to the above-described disadvantages of the prior art, and provides a flat wire wound inductor and a vertical wound inductor.

[0006] A flat wire vertical winding inductor coil is formed by winding a plurality of flat wires, and the inner side of the flat wire is chamfered

The sum of the areas of the chamfers is 3 to 10% of the original cross-sectional area of the flat line.

[0007] Preferably, the inner sides of the flat wire have symmetric chamfering.

[0008] Preferably, the minimum width a of the flat wire is greater than half of the original width W of the flat wire, and the minimum thickness b of the flat wire is greater than half of the original thickness t of the flat wire, that is, a>0.5 W, b>0.5t.

[0009] Preferably, the specification of the flat wire is lmmx3mm, a=2/3W, and b=0.6t.

[0010] Preferably, the flat wire has a specification of 1.2 mm×6 mm, a=2/3 W, and b=2/3 t.

[0011] Preferably, the flat wire has a specification of 1.2 mm x 7 mm, a = 5/7 W, and b = 2/3 t.

[0012] Preferably, the specification of the flat wire is 1.8 mm x 8 mm, a = 4.5 / 8 W, and b = 1.3 / 1.8 t.

[0013] A vertical winding inductor comprising the above-mentioned flat wire vertical winding inductor, a center pillar magnetic core loaded in the flat wire vertical winding inductor, and the outer side of the flat wire vertical winding inductor The cores are joined to form a core yoke that closes the magnetic circuit.

[0014] Preferably, the center pillar magnetic core is formed by stacking a plurality of magnetic cores, and a non-magnetic air gap is disposed between the plurality of magnetic cores.

[0015] Preferably, the magnetic core yoke is formed by stacking a plurality of magnetic cores, and a non-magnetic air gap is disposed between the plurality of magnetic cores.

Advantageous effects of the invention

Beneficial effect [0016] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention performs the inner side of the flat wire by chamfering the flat wire, and then the side of the thin surface is inward, and the winding bending jig is close to the thin surface of the flat wire. Bending and winding, so as to ensure that the thickness of the inner portion of the flat wire after the R angle is bent does not exceed the thickness t of the wire, the vertical winding inductor of L=n xt can be obtained, and the cross-sectional area of the copper wire of the coil There will be no significant reduction to keep the current carrying density close to that of a conventional vertical winding.

Brief description of the drawing

DRAWINGS

1 is a schematic view showing a winding direction of a flat wire vertical winding inductor coil in the prior art;

2 is a schematic view of a flat wire vertical winding inductor coil and a bending angle in the prior art;

3 is a schematic structural view of a flat wire of the present invention;

4 is a schematic cross-sectional view of a flat wire of the present invention;

[0021] FIG. 5 is a schematic view of a flat wire wound inductor and a bent angle of the present invention;

6 is a schematic view showing a flat wire wound inductor and a bent angle of the present invention;

[0023] In the figure: 1, the flat line section; 2, the original section of the flat line; 3, chamfering.

Invention embodiment

Embodiments of the invention

DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present invention will be clearly and completely described in the following with reference to the accompanying drawings in the embodiments of the present invention. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. example. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present invention without creative efforts are within the scope of the present invention.

[0026] As shown in FIGS. 3 to 6, a vertical winding inductor includes a flat wire wound inductor, a center pillar core loaded in the flat wire wound inductor, and the flat wire wound inductor Connecting the middle pillar magnetic core to form a magnetic core yoke for closing the magnetic circuit; the flat wire vertical winding inductor coil is formed by a plurality of 匝 flat wires, and the inner side of the flat wire has a chamfer 3 The area of the chamfer 3 is 3 to 10% of the area of the original section 2 of the flat line, or the inner side of the flat line has a symmetrical chamfer 3, and the sum of the areas of the chamfer 3 is the original section of the flat line. 3 to 10% of the area _; the minimum width a of the flat wire is greater than half of the original width W of the flat wire, and the minimum thickness b of the flat wire is greater than half of the original thickness t of the flat wire, That is, a>0.5W, b>0.5t.

[0027] In one embodiment, the flat wire has a specification of lmm x 3 mm, a=2/3 W, and b=0.6 t.

[0028] In one embodiment, the flat wire has a gauge of 1.2 mm x 6 mm, a = 2/3 W, and b = 2/3 t.

[0029] In one embodiment, the flat wire has a gauge of 1.2 mm x 7 mm, a = 5/7 W, and b = 2/3 t.

[0030] In one embodiment, the flat wire has a gauge of 1.8 mm x 8 mm, a = 4.5/8 W, and b = 1.3/1.8 t.

[0031] In order to achieve a minimum total length of the coil after winding 1^11, the invention has a chamfered area on one side of the flat line, and the chamfered area (loss area) is 3 to 10% of the original cross-sectional area of the flat line. Then, the thin side is turned inward, and the winding bending fixture is pressed against the thin surface of the flat wire to perform inner bending and winding. By reasonably arranging the ratios of a, b and w, t, it is ensured that the R angle is bent and flattened. The thickness of the inner portion of the wire after deformation does not exceed the thickness t of the wire, so that a vertical winding inductor of L=nxt can be obtained, and the cross-sectional area of the copper wire of the coil does not become significantly smaller, so as to remain close to the conventional stand. The current carrying density of the wire wound around the wire.

[0032] The vertical winding inductor coil of the present invention has a magnetic core bar inserted therein, and the vertical winding inductor coil is in a linear direction, and the magnetic core does not bend along the length direction of the coil;

[0033] The vertical winding inductor, the core center pillar, and the core yoke of the present invention have four basic embodiments: a) single winding inductance; b) double winding inductance; c) double winding magnetic integrated inductor; Two-winding magnetically coupled inductor

[0034] The windings of the double-winding and multi-winding inductors of the present invention may be combined in series, parallel, or series-parallel to form different new inductive electromagnetic structures;

[0035] The present invention may also combine the above four basic embodiments to form an inductor of a multi-winding coil;

[0036] The cross-sectional shape of the center pillar magnetic core constituting the inside of the winding of the present invention is not limited to the rectangular or square shape bending winding of the flat wire of the present invention, and is also suitable for increasing the bending radius and winding into a circle. Three basic column cross-sectional shapes such as shape, ellipse and square;

[0037] In the present invention, the core of the magnetic core and the magnetic core yoke may be formed by stacking one or more magnetic cores, and an air gap may be inserted between the magnetic core segments.

[0038] It is apparent to those skilled in the art that the present invention is not limited to the details of the above-described exemplary embodiments, and the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiment should be considered as exemplary and not limited from any point of view. The scope of the present invention is defined by the scope of the appended claims and the claims Any reference signs in the claims should not be construed as limiting the claim.

In addition, it should be understood that although the description is described in terms of embodiments, not every embodiment includes only one independent technical solution, and the description of the specification is merely for the sake of clarity, and those skilled in the art should As a whole, the technical solutions in the embodiments may also be combined as appropriate to form other embodiments that can be understood by those skilled in the art.

Claims

Claim

[Claim 1] A flat wire vertical wound inductor coil, which is formed by winding a plurality of turns of a flat wire, wherein the flat wire has a chamfered inner side, and a sum of areas of the chamfered corners is the flat wire 3 to 10% of the original cross-sectional area.

[Claim 2] The flat wire wound inductor according to claim 1, wherein the inner side of the flat wire has a symmetrical chamfer.

[Claim 3] The flat wire wound inductor according to claim 1, wherein a minimum width a of the flat wire is larger than a half of an original width W of the flat wire, and a minimum thickness of the flat wire b is greater than half of the original thickness t of the flat wire, ie a > 0.5 W, b > 0.5 t.

[Claim 4] The flat wire wound inductor according to claim 3, wherein the flat wire has a specification of lmm x 3 mm, a = 2/3 W, and b = 0.6 t.

[Claim 5] The flat wire wound inductor according to claim 3, wherein the flat wire has a specification of 1.2 mm x 6 mm, a = 2/3 W, and b = 2/3 t.

[Claim 6] The flat wire wound inductor according to claim 3, wherein the flat wire has a specification of 1.2 mm x 7 mm, a = 5/7 W, and b = 2/3 t.

[Claim 7] The flat wire wound inductor according to claim 3, wherein the flat wire has a specification of 1.8 mm x 8 mm, a = 4.5 / 8 W, and b = 1.3 / 1.8 t.

[Claim 8] A vertical winding inductor comprising the flat wire wound inductor of any one of claims 1 to 7, a center pillar core loaded with the flat wire wound inductor, The flat wire is wound around the outer side of the inductor coil to connect the center pillar cores to form a magnetic core yoke for closing the magnetic circuit

[Claim 9] The vertical winding inductor according to claim 8, wherein the center pillar magnetic core is formed by stacking a plurality of magnetic cores, and a non-magnetic air gap is disposed between the plurality of magnetic cores.

[Claim 10] The vertical winding inductor according to claim 8, wherein the magnetic core yoke is formed by stacking a plurality of magnetic cores, and a non-magnetic air gap is disposed between the plurality of magnetic cores.