Bracket device for bearing inductor, inductor device, and uninterruptible power supply

Abstract

The present invention relates to a bracket device for bearing an inductor, an inductor device, and an uninterruptible power supply. The inductor comprises a toroidal magnetic core; and a coil comprising a plurality of wires wound around the toroidal magnetic core. The bracket device comprises: a bracket having a bearing portion adapted to bear the inductor; an insulating pad adapted to be sandwiched between the inductor and the bearing portion of the bracket, the insulating pad having an integrally formed positioning structure capable of being embedded between two adjacent wires of the coil and keeping the toroidal magnetic core fixed; and a fastener adapted to wrap around the toroidal magnetic core and press the toroidal magnetic core together with the insulating pad against the bracket. The bracket device of the present invention is capable of effectively fixing an inductor and allowing it to dissipate heat well.

Claims

1. A device for bearing an inductor that includes a toroidal magnetic core and a coil that includes a plurality of wires wound around the toroidal magnetic core, the device comprises: a bracket having a bearing portion to bear the inductor; an insulating pad located between the inductor and the bearing portion of the bracket, the insulating pad having an integrated positioning structure configured to extend between two adjacent wires of the coil to contact the toroidal magnetic core; and a fastener configured to wrap around the toroidal magnetic core to couple the toroidal magnetic core and the insulating pad to the bracket.

2. The device according to claim 1, wherein the integrated positioning structure has two opposing clamping projections extending in a direction away from the bracket, and a recess, formed between the two clamping projections, configured to receive the toroidal magnetic core.

3. The device according to claim 1, wherein the insulating pad comprises: a base configured to abut against the bearing portion of the bracket; and a shim extending from the base in a direction away from the bracket, the integrated positioning structure being formed at a free end of the shim away from the bracket.

4. The device according to claim 3, wherein the insulating pad comprises a plurality of shims spaced apart, wherein each shim is configured to be inserted between the two adjacent wires of the coil, and when the inductor is borne on the device, the free end of each of the plurality of shims points to a central axis of the toroidal magnetic core.

5. The device according to claim 1, wherein the insulating pad has an opening through which the fastener passes.

6. The device according to claim 1, wherein the bearing portion of the bracket has an arcuate bearing surface, a curvature of the arc being configured to an outer circumference of the coil, and the bracket having an opening through which the fastener passes.

7. The device according to claim 1, wherein the bracket further comprises a mounting portion connected to the bearing portion, and the mounting portion comprises a hook and/or a mounting hole.

8. The device according to claim 1, wherein all or at least a portion of the fastener in contact with the inductor is insulative.

9. A inductor device comprising: a toroidal magnetic core; and a coil comprising a plurality of wires wound around the toroidal magnetic core, wherein the device comprises: a bracket having an insulating bearing portion and an insulating positioning structure integrally formed on the bearing portion, the positioning structure configured to extend between two adjacent wires of the coil to contact the toroidal magnetic core; and a fastener configured to wrap around the toroidal magnetic core to couple the toroidal magnetic core to the bracket.

10. An inductor device, comprising: an inductor having a toroidal magnetic core and a coil including a plurality of wires wound around the toroidal magnetic core; and a bracket device for bearing the inductor, wherein the bracket device comprises the device according to claim 1.

11. An uninterruptible power supply, comprising an inductor device, wherein the inductor device is the inductor device according to claim 10.

12. A bracket comprising: a bearing portion having a curvature that is configured to receive an inductor with a toroidal magnetic core having about the same curvature as the bearing portion, and the toroidal magnetic core is wound by a coil comprising a plurality of turns of a wire; an insulating pad located between the inductor and the bearing portion of the bracket, the insulating pad including a curved surface; and a plurality of positioning structures spaced apart along the curved surface of the insulating pad and radially extending from the curved surface of the insulating pad toward a center of the inductor to pass between respective adjacent ones of the plurality of turns of the wire of the coil to contact the toroidal magnetic core.

13. The bracket of claim 12 a fastener configured to wrap around the toroidal magnetic core and extending between at least one pair of the plurality of turns of the wire to contact the bracket.

14. The bracket of claim 12, wherein each of the positioning structures comprises a shim having a remote end with a recess that is shaped to contact three surfaces of the toroidal magnetic core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the present invention are described in detail in the following with reference to the accompanying drawings, wherein:

(2) FIG. 1 is a schematic perspective view of an inductor device according to an embodiment of the present invention;

(3) FIG. 2 is a schematic planar view of an inductor device according to an embodiment of the present invention;

(4) FIG. 3 is a perspective sectional view of an inductor device according to an embodiment of the present invention;

(5) FIG. 4 is a schematic exploded view of an inductor device according to an embodiment of the present invention;

(6) FIG. 5 is a schematic planar view of a bracket suspended from a mounting base according to an embodiment of the present invention; and

(7) FIG. 6 is a schematic perspective view of a fastener according to an embodiment of the present invention.

DESCRIPTION OF THE REFERENCE NUMERALS

(8) 1. Inductor Device 2. Inductor 20. Toroidal Magnetic Core 22. Coil 220. Wire 3. Bracket Device 4. Bracket 40. Bearing Portion 42. Mounting Portion 420. Hook 422. Limiting Member 424. Mounting Hole 44. Opening 46. Opening 5. Insulating Pad 50. Base 52. Shim 522. Clamping Projection 524. Recess 54. Opening 56. Opening 6. Fastener 7. Mounting Base

DETAILED DESCRIPTION

(9) A schematic scheme of the disclosed device is described in detail with reference to the accompanying drawings. Although providing the accompanying drawings is to present some implementations of the present invention, the accompanying drawings do not need to be drawn according to the size of particular embodiments, and certain features can be enlarged, removed, or locally exploded to better illustrate and explain the disclosure of the present invention. Part of members in the accompanying drawings can be positionally adjusted according to actual requirements without affecting the technical effect. In the description, the term “in the accompanying drawings” or similar terms do not necessary refer to all of the accompanying drawings or examples.

(10) Some directional terms used in the following to describe the accompanying drawings, such as “in,” “out,” “upper,” and “lower,” and other directional terms are construed as having normal meanings thereof and refer to those directions involved when the accompanying drawings are viewed normally. Unless otherwise specified, the directional terms in the description are substantially in accord with conventional directions understood by those skilled in the art.

(11) The terms “first,” “first one,” “second,” and “second one” and similar terms used in the present invention do not indicate any sequence, number, or importance in the present invention, and are used only to distinguish one component from other components.

(12) The term “integral molding” as used in the present invention relates to a part comprising two or more portions/components, wherein the part is either integrally formed and the portions/components are not divided during processing of the part, or the portions/components are separately processed and then combined together by appropriate securing and connection means (such as bonding, melting, mechanical connection such as snapping, screwing, tight fitting, etc.) such that the portions/components cannot move in the finally formed part. Both of the above two methods are encompassed by the “integral molding” described in the present invention.

(13) FIG. 1 to FIG. 4 schematically show an embodiment of an inductor device of the present invention. The inductor device is applicable to an uninterruptible power supply. In the shown embodiment, the inductor device 1 includes an inductor 2 and a bracket device 3 bearing the inductor 2. The inductor 2 includes a toroidal magnetic core 20 and a coil 22 wound around the toroidal magnetic core 20. The coil 22 consists of a plurality of copper wires 220 each wound around the magnetic core 20.

(14) The bracket device 3 includes a bracket 4, an insulating pad 5 sandwiched between the bracket 4 and the inductor 2, and a fastener 6 that fastens the bracket 4, the insulating pad 5, and the inductor 2 together. As shown in FIG. 4, the bracket 4 may be, for example, a one-piece metal member made of a metal plate (for example, an aluminum plate) having a uniform thickness, so that the bracket 4 has sufficient mechanical strength to avoid deformation when bearing the inductor 2. The bracket 4 includes a bearing portion 40 for bearing the inductor 2 and a mounting portion 42 that is connected to the bearing portion 40 and used for mounting the bracket 4 on a mounting base (indicated by numeral “7” in FIG. 5). The bearing portion 40 is a curved plate, the curvature thereof being adapted to the outer circumference of the coil 22 of the inductor 2, thereby providing the inductor 2 with improved stable bearing. In an embodiment not shown, it is also possible to construct only a bearing surface of the bearing portion 40 facing the inductor 2 as a curved surface adapted to the outer circumference curvature of the coil 22 of the inductor 2; further, the surface of the bearing portion 40 opposing the inductor 2 can be planar or of other configurations.

(15) As shown in FIG. 1 and FIG. 4, the mounting portion 42 includes a hook 420 and a mounting hole 424 in the shown embodiment, wherein the hook 420 is formed by integral bending at one end of the bearing portion 40 (at the upper end of the bearing portion 40 with the suspended bracket 4 as shown in FIG. 5 as a reference), whereas the mounting hole 424 is formed at the other end of the bearing portion 40 opposite to the end where the hook 420 is positioned (at the lower end of the bearing portion 40 with the suspended bracket 4 as shown in FIG. 5 as a reference). With reference to FIG. 5, the bracket 4 is suspended from the mounting base 7 by means of the hook 420 and secured in place by means of a bolt passing through the mounting hole 424. The mounting base 7 may be, for example, a vertical wall of a cabinet of an uninterruptible power supply.

(16) It is conceivable that either of the hook 420 and the mounting hole 424 is used, or other positioning portions are used in place of the hook 420 and the mounting hole 424. For example, a positioning hole is opened in the mounting base 7, and a positioning member for inserting/snapping in the positioning hole is formed on the bracket. Alternatively, an adhesive is applied between the bracket and the mounting base 7 as a positioning portion.

(17) In order to further limit movement of the bracket 4 relative to the mounting base 7, a limiting member 422 may be formed on each of two opposite sides of the hook 420, and the limiting member 422 is formed by, for example, bending a part of the metal plate in a direction opposite to the bending direction of the hook 420. As shown in FIG. 5, after the bracket 4 is suspended from the mounting base 7, the mounting base 7 is positioned between the hook 420 and the limiting member 422. Specifically, a side of the hook 420 facing the mounting base 7 rests on a first surface of the mounting base 7 or is only slightly spaced from the first surface, whereas a side of the limiting member 422 facing the mounting base 7 rests on a second surface of the mounting base 7 opposite to the first surface or is only slightly spaced from the second surface.

(18) It should be noted that the division of the bracket into the bearing portion and the mounting portion herein is only considered for the purpose of distinguishing between functions and for ease of description; this technical solution does not suggest that a physical boundary/structure that can clearly identify their respective regions is necessarily present on the bracket, regardless of whether the bracket is integrally formed or assembled from a plurality of components/portions.

(19) The structure of the insulating pad 5 can be better understood by referring to FIG. 2 to FIG. 4. The insulating pad 5 is made of an insulating material and is preferably made of a tough or flexible insulating material such as rubber, plastic, silicone, and etc. that is capable of completely isolating the bracket 4 from the inductor 2. In the shown embodiment, the insulating pad 5 includes a substantially sheet-shaped base 50 and five shims 52 extending from the base 50 in a direction away from the bracket 4. In other embodiments, the number of shims 52 can be increased or decreased according to requirements, such as the number of wires in the coil or the diameter of the coil. The shims 52 of the insulating pad 5 are integrally formed with the base 50, for example, the insulating pad 5 is formed by an integral molding process, or the shims 52 are secured to the base 50 by means of bonding, melting, welding, or mechanical connection, etc., so that no relative movement can be generated between the shims 52 and the base 50. Each shim 52 can be inserted between two adjacent wires 220 of the coil 22 and bears and holds the toroidal magnetic core 20 to prevent axial and circumferential movements thereof, and the cushion can provide a vibration and noise reduction effect.

(20) As shown in the figure, in an assembled state, free ends of the shims 52 away from the base 50 substantially point to the central axis of the toroidal magnetic core 20 so that the shims 52 can be inserted between the wires 220 more smoothly. In this state, the insulating pad 5, as a whole and as viewed from its axial projection, conforms to the curvature of the bearing portion 40 of the bracket 4 and the outer circumference curvature of the toroidal magnetic core 20, thereby better conforming to the bearing portion 40 and providing the toroidal magnetic core 20 with improved stable bearing. The shims 52 may be wedge-shaped with a cross-sectional area tapered in a direction away from the base 50 to better accommodate gaps between two adjacent wires 220 of the coil 22.

(21) The insulating pad 5 bears and holds the toroidal magnetic core 20 by means of a positioning structure formed at the free ends of the shims 52. In the shown embodiment, the positioning structure includes two opposing clamping projections 522 that extend away from the bracket 4 and a recess 524 formed between the two clamping projections 522. In the assembled state, a portion of the toroidal magnetic core 20 is received in the recess 524, and since the insulating pad 5 uses a flexible material, the two clamping projections 522 can be clamped on opposite end faces of the toroidal magnetic core 20. The outer peripheral surface of the toroidal magnetic core 20 is preferably capable of abutting against the bottom surface of the recess 524. In addition, an adhesive may further be applied between the surfaces of the clamping projections and/or the surfaces of the recess and the toroidal magnetic core 20 to further secure the toroidal magnetic core 20 and the insulating pad 5 together. Alternatively or optionally, an adhesive may be applied between the insulating pad 5 and the wires 220 to secure the two together.

(22) Alternatively, the bracket and the insulating pad may be integrated together. For example, the bracket is entirely made of an insulating material; or the bearing portion of the bracket for bearing the inductor is made of an insulating material; and the insulating shims are integrally formed on the bearing portion and a positioning structure is provided at their free ends. For example, the bracket comprising the insulating shims is formed by an integral molding process, or the insulating shims are secured to the bearing portion of the bracket by means of bonding, melting, welding, or mechanical connection, so that no relative movement can be generated between the insulating shims and the bearing portion of the bracket. For other structures of the bracket, such as the curvature of the bearing portion and the mounting portion, reference may be made to the metal bracket described above; as for other structures of the insulating shims, such as the positioning structure, reference may be made to the shims in the insulating pad described above.

(23) Compared with the prior art, the present invention fixes the inductor by securing the magnetic core, instead of fixing an inductor by means of a coil. The size of the positioning structure can be appropriately reduced in accordance with a gap size between two adjacent wires, so that a gap is formed between the positioning structure and the two wires around, so as to avoid impact on the coil.

(24) As shown in FIG. 6, the fastener 6 is a closed ring that is wound around the toroidal magnetic core 20; the bracket 4 in an assembled state to press the toroidal magnetic core 20 together with the insulating pad 5 against the bracket 4. Alternatively, the fastener may be adjustable in length. For example, the fastener is of an elongated shape having two ends, both ends being provided with engaging snaps that are movable in the length direction of the fastener. Alternatively, the fastener 6 may be wound around only the toroidal magnetic core 20 and secured to a connection structure of the bracket 4.

(25) The fastener 6 may be made, for example, of stainless steel to provide sufficient structural strength, and may be coated with an insulating layer at a position where the fastener 6 is in contact with or is possibly in contact with the toroidal magnetic core 20 and the coil 22. Alternatively, the fastener 6 may also be directly made of an insulating material that is preferably less elastic.

(26) Two fasteners 6 are shown in the figure, but those skilled in the art will understand that the number of fasteners 6 can be correspondingly increased or decreased depending on actual needs, such as the volume, weight, etc. of the inductor.

(27) In the shown embodiment, an opening 44 is provided at one end of the bracket 4 and an opening 46 is provided at the other end, while an opening 54 is provided at one end of the base 50 of the insulating pad 5 and an opening 56 is provided at the other end. In the assembled state, the fastener 6 is wound around the outer circumference of the toroidal magnetic core 20 and passes through the openings 44 and 46 of the bracket 4 and the openings 54 and 56 of the insulating pad 5, thereby tightening the inductor 2 to the bracket device 3. Alternatively, the openings on the bracket and the insulating pad may be replaced with recesses. Alternatively, the openings of the bracket 4 may be omitted, or the openings of the insulating pad 5 may be omitted, or both the openings of the bracket 4 and the insulating pad 5 may be omitted.

(28) It should be understood that although the description is presented according to each embodiment, each embodiment does not necessarily include only one independent technical solution. The presentation manner of the description is merely for clearness, and those skilled in the art should regard the description as a whole, and the technical solutions in the embodiments can also be appropriately combined to form other implementations comprehensible by those skilled in the art.

(29) What is described above is merely exemplary specific implementations of the present invention, but is not intended to limit the scope of the present invention. Any equivalent change, modification, or combination made by those skilled in the art without departing from the conception and principle of the present invention shall fall within the protection scope of the present invention.