Inductors with core structure supporting multiple air flow modes

Patent metadata

Field	Value
Publication number	US-11508510-B2
Application number	US-202016784335-A
Country	US
Kind code	B2
Filing date	Feb 7, 2020
Priority date	Feb 8, 2019
Publication date	Nov 22, 2022
Grant date	Nov 22, 2022

Abstract

An inductor includes a plurality of stacked core parts having aligned central openings, at least one spacer separating the core parts from one another, and a winding comprising a plurality turns wound around the stack of core parts through central openings of the core parts. The at least one spacer may include respective groups of spacers disposed between respective pairs of the core parts. In some embodiments, the at least one spacer may include a plurality of spacers disposed between first and second ones of the core parts and radially distributed in a circular pattern aligned with the first and second core parts.

First claim

That which is claimed:

1. An inductor comprising:
a plurality of stacked core parts having aligned central openings;
a winding comprising a plurality turns wound around the stack of core parts through central openings of the core parts; and
a plurality of spacers separating the core parts from one another, each of which comprises a first portion disposed between adjacent ones of the core parts and a second portion extending from the first portion and disposed in respective gaps between adjacent ones of the turns.

2. The inductor of claim 1 , wherein the spacers are radially distributed in a circular pattern aligned with the first and second core parts.

3. The inductor of claim 1 , further comprising a plug spacer disposed between a major surface of one of the core parts and the winding and configured to deflect an air flow through the central openings of the core parts.

4. The inductor of claim 3 , wherein the plug spacer comprises a disc having a plurality of slots therein that receive respective turns of the winding.

5. The inductor of claim 1 , wherein the spacers comprise a thermally conductive and electrically insulating material.

6. The inductor of claim 1 , wherein each spacer of the plurality of spacers further comprises a third portion extending from the first portion and having at least a portion disposed in central openings of the adjacent core parts.

7. An inductor comprising:
a first core part;
a second core part having a central opening aligned with a central opening of the first core part;
a winding wound around the first and second core parts through the central openings thereof and comprising a plurality of turns distributed around the first and second core parts; and
a plurality of spacers disposed between the first and second core parts, radially distributed in a circular pattern aligned with the first and second core parts and disposed at respective gaps between adjacent turns of the windings.

8. The inductor of claim 7 , wherein the spacers respectively comprise portions separating adjacent turns of the winding.

9. The inductor of claim 7 , wherein each of the spacers comprises:
a first portion disposed between the first and second core parts; and
a second portion extending from the first portion and disposed between adjacent turns of the winding.

10. The inductor of claim 9 , wherein each of the spacers further comprises a third portion extending from the first portion and disposed in the central openings of the first and second core parts.

11. The inductor of claim 7 , wherein the spacers comprise a thermally conductive and electrically insulating material.

Assignees

• Eaton Intelligent Power Ltd

Inventors

• Xu Zelin
• Juds Mark A
• Rosales Jose Antonio Trujillo

Classifications

• H01F27/263

  Fastening parts of the core together · CPC title

• H01F3/14 Primary

  Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) · CPC title

• H01F27/28

  Coils; Windings; Conductive connections · CPC title

• H01F27/085 Primary

  Cooling by ambient air · CPC title

• H01F27/2895

  Windings disposed upon ring cores · CPC title