A coupled inductor and a method for manufacturing the same

Abstract

The present invention discloses a coupled inductor and a method for manufacturing the same, comprising a base block box (10), a base block plug (20) inserted into the base block box (10), and a coil group (30) arranged between the base block plug (20) and the base block box (10); the coil group (30) is embedded in the base block box (10); the present invention prepares a magnet of a specific structure with a specific composite material, and prepares the coupled inductor in combination with a specific process, so that the obtained coupled inductor has excellent inductance performance. Specifically, by using a specific composite material in combination with a specific cold pressing forming process, a base block box and a base block plug of a specific structure are first prepared, and then the primary coil and the secondary coil are sequentially embedded into the base block box groove, the base block column is embedded in the base block box groove, and then a formed assembly is formed by a specific hot pressing forming process, which effectively solves the problem of only one coil in a traditional inductor, and effectively improves the performance and operation speed of the circuit board product within the limited space of the circuit board.

Description

Technical Field

[0001] The invention relates to a coupled inductor and a manufacturing method thereof, belonging to the technical field of inductors. Background Art

[0002] AI computing power refers to the ability to perform artificial intelligence computing and related infrastructure.

[0003] AI computing requires powerful computer performance, high-speed data processing capabilities, efficient algorithm optimization, etc. Only with sufficient AI computing power can high-quality AI computing be guaranteed. AI computing power can be achieved through clusters, cloud computing, dedicated AI acceleration cards, etc. As AI application scenarios continue to expand and applications deepen, the demand for AI computing power is also rising rapidly.

[0004] With the development of AI technology, the performance requirements for hardware equipment are becoming increasingly stringent, especially the local power requirements are increasing. However, the voltage input to the IC is usually designed to be lower and lower. In order to meet the power requirements, increasing the current has become the only choice in circuit design. On the other hand, taking electronic devices such as automotive 5G communication modules and artificial intelligence terminals as examples, considering the particularity of the application scenarios, when conceiving and designing power inductors, their external dimensions, internal structures, etc. have relatively strict requirements. How to improve the performance and computing speed of the product while taking into account the full utilization of the internal space of the equipment and the tight arrangement of various electronic components inside the equipment has become extremely urgent.

[0005] Therefore, the present application proposes a coupled inductor and a manufacturing method thereof to meet market demand. Summary of the invention

[0006] In order to solve the above-mentioned technical problems, the present invention discloses a coupled inductor and a manufacturing method thereof.

[0007] The technical solution adopted by the present invention is: to provide a coupled inductor, including a base block box, a base block plug inserted into the base block box, and a coil group arranged between the base block plug and the base block box; the coil group is connected to the base block box in an embedded manner.

[0008] Preferably, the base block box includes a shell, and two partition columns are respectively arranged on the left and right side surfaces of the shell; the two partition columns are respectively arranged at the center positions of the left and right side surfaces, and form four avoidance grooves with the front and rear side surfaces.

[0009] Preferably, the base block box further comprises two short stop columns arranged at the inner bottom of the shell body, and two long stop columns corresponding to the short stop columns; the two short stop columns are respectively arranged on both sides of the right partition column; the two long stop columns are respectively arranged on both sides of the left partition column.

[0010] Preferably, the base block plug comprises a base block cover and a base block column arranged below the base block cover; the base block plug is inserted into the base block box through the base block column.

[0011] Preferably, the coil group includes a main coil and a secondary coil arranged on the main coil; the main coil and the secondary coil are embedded in the base block box in sequence.

[0012] Preferably, the main coil includes a U-shaped main coil, two main vertical coils arranged at both ends of the U-shaped main coil, and two main horizontal coils arranged on the two main vertical coils; after the U-shaped main coil, the main vertical coil and the main horizontal coil are combined into one, they are viewed from the side as a Z shape.

[0013] Preferably, the secondary coil comprises a U-shaped secondary coil, two secondary vertical coils arranged at both ends of the U-shaped secondary coil, and two secondary horizontal coils arranged on the two secondary vertical coils; after the U-shaped secondary coil, the secondary vertical coil and the secondary horizontal coil are combined into one, they are viewed from the side as a Z shape.

[0014] A method for manufacturing a coupled inductor comprises the following steps:

[0015] S1: prefabricate a base block box mold and a base block plug mold according to the specifications and sizes of the base block box and the base block plug, fill the corresponding molds with manganese-zinc ferrite powder and mold them to obtain a base block box and a base block plug with improved forming density;

[0016] S2: Take the conductive metal sheet according to the specifications of the primary coil and the secondary coil, and bend it into shape;

[0017] S3: Spray a layer of organic material on the surface of the formed primary coil and secondary coil for insulation treatment;

[0018] S4: The two main vertical coils on the main coil are respectively embedded in the two right side avoidance grooves of the base block box, and then pushed downward until the main coil is against the short stop column in the base block box, and the two main horizontal coils on the main coil buckle the right side opening of the base block box;

[0019] S5: The two secondary vertical coils on the secondary coil are respectively embedded in the two left avoidance grooves of the base block box, and then pushed downward until the secondary coil is against the long stop column in the base block box, and the two secondary horizontal coils on the secondary coil buckle the left opening of the base block box;

[0020] S6: Next, insert the base block column in the base block plug into the U-shaped grooves of the primary coil and the secondary coil until the base block cover in the base block plug abuts against the two primary horizontal coils and the two secondary horizontal coils;

[0021] S7: Finally, the base block box, the base block plug and the coil group are formed into one piece by hot pressing through the mold and the machine.

[0022] Preferably, in S7, the hot pressing temperature is 130-150°C; and / or the hot pressing pressure is 6.5-7.5 T / cm2; and / or the hot pressing time is 85-120s.

[0023] Beneficial effects of the present invention:

[0024] The present invention prepares a magnet of a specific structure with a specific composite material, and prepares a coupled inductor in combination with a specific process, so that the obtained coupled inductor has excellent inductance performance. Specifically, by using a specific composite material in combination with a specific cold pressing process, a base block box and a base block plug of a specific structure are first prepared, and then the main coil and the secondary coil are sequentially embedded into the base block box groove, and the base block column of the base block plug is embedded in the base block box groove, and then a formed component is formed through a specific hot pressing process, which effectively solves the problem of only one coil in a traditional inductor, and effectively improves the performance and operation speed of the circuit board product within the limited space of the circuit board. In addition, the present invention can effectively reduce the risk of product cracking and reduce the thermal expansion problem caused by rapid high-temperature curing of the formed component by adopting low-temperature and high-pressure forming technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a three-dimensional structural schematic diagram of a coupled inductor;

[0026] Figure 2 yes Figure 1 A schematic diagram of the cross-sectional structure of;

[0027] Figure 3 yes Figure 1 A schematic diagram of the three-dimensional structure of the middle base block box;

[0028] Figure 4 yes Figure 1 A schematic diagram of the three-dimensional structure of the middle base block plug;

[0029] Figure 5 yes Figure 2 Schematic diagram of the three-dimensional structure of the main coil;

[0030] Figure 6 yes Figure 2 Schematic diagram of the three-dimensional structure of the secondary coil. DETAILED DESCRIPTION

[0031] The present invention will be further described below in conjunction with specific drawings.

[0032] like Figures 1 to 6 As shown, a coupled inductor is provided, including a base block box 10, a base block plug 20 inserted into the base block box 10, and a coil group 30 arranged between the base block plug 20 and the base block box 10; the coil group 30 is connected to the base block box 10 in an embedded manner.

[0033] like Figure 1 As shown, the block box 10 and the block plug 20 are magnets; the coil group 30 body is embedded in the block box 10, and the end is placed at the opening edge of the block box 10; then the block plug 20 is inserted into the block box 10, and at this time the end of the coil group 30 is between the block box 10 and the block plug 20.

[0034] Furthermore, the base block box 10 includes a shell 11, and two partition columns 12 are respectively arranged on the left and right side surfaces of the shell 11; the two partition columns 12 are respectively arranged at the center positions of the left and right side surfaces, and form four avoidance grooves 13 with the front and rear side surfaces.

[0035] Furthermore, the base block box 10 also includes two short blocking columns 14 arranged at the inner bottom of the shell 11, and two long blocking columns 15 corresponding to the short blocking columns 14; the two short blocking columns 14 are respectively arranged on both sides of the right partition column 12; the two long blocking columns 15 are respectively arranged on both sides of the left partition column 12.

[0036] like Figure 2 and Figure 3 As shown, the cross-sectional groove of the shell 11 is H-shaped; the coil assembly 30 is inserted into the shell 11 through four avoidance grooves 13 and placed above the short stop column 14 and the long stop column 15; and then the base block plug 20 is inserted into the H-shaped cross-sectional groove of the shell 11.

[0037] Furthermore, the block plug 20 includes a block cover 21 and a block column 22 disposed below the block cover 21 ; the block plug 20 is inserted into the block box 10 through the block column 22 .

[0038] like Figure 2 and Figure 4 As shown, the base block plug 20 is inserted into the H-shaped cross-section groove of the housing 11 through the base block column 22; the base block cover 21 is placed above the coil assembly 30.

[0039] Furthermore, the coil assembly 30 includes a main coil 31 and a secondary coil 32 disposed on the main coil 31 ; the main coil 31 and the secondary coil 32 are sequentially embedded in the base block box 10 .

[0040] like Figure 2 As shown, the secondary coil 32 is placed on the primary coil 31 in a stacked manner.

[0041] Furthermore, the main coil 31 includes a U-shaped main coil 311, two main vertical coils 312 arranged at both ends of the U-shaped main coil 311, and two main horizontal coils 313 arranged on the two main vertical coils 312; after the U-shaped main coil 311, the main vertical coil 312 and the main horizontal coil 313 are combined into one, they are a Z shape when viewed from the side.

[0042] Furthermore, the secondary coil 32 includes a U-shaped secondary coil 321, two secondary vertical coils 322 arranged at both ends of the U-shaped secondary coil 321, and two secondary horizontal coils 323 arranged on the two secondary vertical coils 322; after the U-shaped secondary coil 321, the secondary vertical coil 322 and the secondary horizontal coil 323 are combined into one, they form a Z shape when viewed from the side.

[0043] like Figure 2 and Figure 5 As shown, the main coil 31 is first inserted into the H-shaped cross-section groove of the shell 11 through the U-shaped main coil 311. At this time, the two main vertical coils 312 are just embedded in the two avoidance grooves 13 on the right side of the shell 11. During the pushing process, the two main vertical coils 312 just rest against the two short blocking columns 14 on the right side of the shell 11, and the two main horizontal coils 313 are just buckled on the opening edge on the right side of the shell 11.

[0044] Then insert the secondary coil 32 into the H-shaped cross-section groove of the shell 11 through the U-shaped secondary coil 321. At this time, the two secondary vertical coils 322 are just embedded in the two avoidance grooves 13 on the left side of the shell 11. During the pushing process, the two secondary vertical coils 322 just rest against the two long blocking columns 15 on the left side of the shell 11, and the two secondary horizontal coils 323 are just buckled on the left side opening edge of the shell 11.

[0045] Then insert the block column 22 of the block plug 20 into the H-shaped cross-sectional groove of the shell 11, and then insert it into the U-shaped groove of the U-shaped secondary coil 321 and the U-shaped main coil 311 in sequence, until the head of the block column 22 touches the bottom of the shell 11; at this time, the block cover 21 just contacts with the main horizontal coil 313 and the secondary horizontal coil 323, and then it is made into a whole by hot pressing.

[0046] Example 1

[0047] A method for manufacturing a coupled inductor comprises the following steps:

[0048] S1: prefabricate a mold for the block box 10 and a mold for the block plug 20 according to the specifications and sizes of the block box 10 and the block plug 20, fill the corresponding molds with manganese-zinc ferrite powder and mold them to obtain a block box 10 and a block plug 20 with improved molding density;

[0049] S2: Take a conductive metal sheet according to the specifications of the primary coil 31 and the secondary coil 32 and bend it into shape;

[0050] S3: spraying a layer of organic material on the surface of the formed primary coil 31 and the secondary coil 32 for insulation treatment;

[0051] S4: The two main vertical coils 312 on the main coil 31 are respectively embedded in the two right side avoidance grooves 13 of the base block box 10, and then pushed downward until the main coil 31 is against the short stop column 14 in the base block box 10, and the two main horizontal coils 313 on the main coil 31 buckle the right side opening of the base block box 10;

[0052] S5: The two secondary vertical coils 322 on the secondary coil 32 are respectively embedded in the two left avoidance grooves 13 of the base block box 10, and then pushed downward until the secondary coil 32 abuts against the long stop column 15 in the base block box 10, and the two secondary horizontal coils 323 on the secondary coil 32 buckle the left opening of the base block box 10;

[0053] S6: Next, the block column 22 in the block plug 20 is inserted into the U-shaped grooves of the primary coil 31 and the secondary coil 32 until the block cover 21 in the block plug 20 abuts against the two primary horizontal coils 313 and the two secondary horizontal coils 323;

[0054] S7: Finally, the base block box 10, the base block plug 20 and the coil assembly 30 are formed into one body by hot pressing through the mold and the machine, the hot pressing temperature is 130°C; the hot pressing pressure is 7.5T / cm2; and the hot pressing time is 120s.

[0055] In this embodiment 1, the coupled inductor obtained has good performance and has no cracking and thermal expansion problems.

[0056] Example 2

[0057] A method for manufacturing a coupled inductor comprises the following steps:

[0058] S1: prefabricate a mold for the block box 10 and a mold for the block plug 20 according to the specifications and sizes of the block box 10 and the block plug 20, fill the corresponding molds with manganese-zinc ferrite powder and mold them to obtain a block box 10 and a block plug 20 with improved molding density;

[0059] S2: Take a conductive metal sheet according to the specifications of the primary coil 31 and the secondary coil 32 and bend it into shape;

[0060] S3: spraying a layer of organic material on the surface of the formed primary coil 31 and the secondary coil 32 for insulation treatment;

[0061] S4: The two main vertical coils 312 on the main coil 31 are respectively embedded in the two right side avoidance grooves 13 of the base block box 10, and then pushed downward until the main coil 31 is against the short stop column 14 in the base block box 10, and the two main horizontal coils 313 on the main coil 31 buckle the right side opening of the base block box 10;

[0062] S5: The two secondary vertical coils 322 on the secondary coil 32 are respectively embedded in the two left avoidance grooves 13 of the base block box 10, and then pushed downward until the secondary coil 32 abuts against the long stop column 15 in the base block box 10, and the two secondary horizontal coils 323 on the secondary coil 32 buckle the left opening of the base block box 10;

[0063] S6: Next, the block column 22 in the block plug 20 is inserted into the U-shaped grooves of the primary coil 31 and the secondary coil 32 until the block cover 21 in the block plug 20 abuts against the two primary horizontal coils 313 and the two secondary horizontal coils 323;

[0064] S7: Finally, the base block box 10, the base block plug 20 and the coil assembly 30 are formed into one body by hot pressing through the mold and the machine, the hot pressing temperature is 140°C; the hot pressing pressure is 7.0T / cm2; and the hot pressing time is 100s.

[0065] In this embodiment 2, the coupled inductor obtained has good performance and has no cracking and thermal expansion problems.

[0066] Example 3

[0067] A method for manufacturing a coupled inductor comprises the following steps:

[0068] S1: prefabricate a mold for the block box 10 and a mold for the block plug 20 according to the specifications and sizes of the block box 10 and the block plug 20, fill the corresponding molds with manganese-zinc ferrite powder and mold them to obtain a block box 10 and a block plug 20 with improved molding density;

[0069] S2: Take a conductive metal sheet according to the specifications of the primary coil 31 and the secondary coil 32 and bend it into shape;

[0070] S3: spraying a layer of organic material on the surface of the formed primary coil 31 and the secondary coil 32 for insulation treatment;

[0071] S4: The two main vertical coils 312 on the main coil 31 are respectively embedded in the two right side avoidance grooves 13 of the base block box 10, and then pushed downward until the main coil 31 is against the short stop column 14 in the base block box 10, and the two main horizontal coils 313 on the main coil 31 buckle the right side opening of the base block box 10;

[0072] S5: The two secondary vertical coils 322 on the secondary coil 32 are respectively embedded in the two left avoidance grooves 13 of the base block box 10, and then pushed downward until the secondary coil 32 abuts against the long stop column 15 in the base block box 10, and the two secondary horizontal coils 323 on the secondary coil 32 buckle the left opening of the base block box 10;

[0073] S6: Next, the block column 22 in the block plug 20 is inserted into the U-shaped grooves of the primary coil 31 and the secondary coil 32 until the block cover 21 in the block plug 20 abuts against the two primary horizontal coils 313 and the two secondary horizontal coils 323;

[0074] S7: Finally, the base block box 10, the base block plug 20 and the coil assembly 30 are formed into one body by hot pressing through the mold and the machine, the hot pressing temperature is 150°C; the hot pressing pressure is 6.5T / cm2; and the hot pressing time is 85s.

[0075] In this embodiment 3, the coupled inductor obtained has good performance and has no cracking and thermal expansion problems.

[0076] The above description is only a preferred embodiment of the present invention, which is only illustrative and not restrictive of the present invention. Those skilled in the art understand that many changes, modifications, and even equivalences may be made to the present invention within the spirit and scope defined by the claims of the present invention, but all of them will fall within the scope of protection of the present invention.

Claims

1. A coupled inductor, characterized in that: The invention comprises a base block box (10), a base block plug (20) inserted into the base block box (10), and a coil group (30) arranged between the base block plug (20) and the base block box (10); the coil group (30) is connected to the base block box (10) by embedding; the base block box (10) comprises a shell (11), and two partition columns (12) respectively arranged on the left and right side surfaces of the shell (11); the two partition columns (12) are respectively arranged at the center positions of the left and right side surfaces, and form four avoidance grooves (13) with the front and rear side surfaces; the base block box (10) also comprises two short stop columns (14) arranged at the bottom of the inner side of the shell (11), and two long stop columns (15) corresponding to the short stop columns (14); the two short stop columns (14) are respectively arranged on the two sides of the right side partition column (12); the two long stop columns (15) are respectively arranged on the two sides of the left side partition column (12); The base block plug (20) comprises a base block cover (21) and a base block column (22) arranged below the base block cover (21); the base block plug (20) is inserted into the base block box (10) through the base block column (22); The coil assembly (30) comprises a main coil (31) and a secondary coil (32) arranged on the main coil (31); the main coil (31) and the secondary coil (32) are sequentially embedded in a base block box (10); the main coil (31) abuts against a short stopper (14) in the base block box (10); and the secondary coil (32) abuts against a long stopper (15) in the base block box (10); The main coil (31) comprises a U-shaped main coil (311), two main vertical coils (312) arranged at two ends of the U-shaped main coil (311), and two main horizontal coils (313) arranged on the two main vertical coils (312); when the U-shaped main coil (311), the main vertical coil (312) and the main horizontal coil (313) are combined into one body, a Z shape is formed when viewed from the side; the two main vertical coils (312) abut against two short stop posts (14) on the right side of the housing (11); The secondary coil (32) comprises a U-shaped secondary coil (321), two secondary vertical coils (322) arranged at two ends of the U-shaped secondary coil (321), and two secondary horizontal coils (323) arranged on the two secondary vertical coils (322); when the U-shaped secondary coil (321), the secondary vertical coil (322) and the secondary horizontal coil (323) are combined into one, they are in a Z shape when viewed from the side; the two secondary vertical coils (322) are against two long blocking columns (15) on the left side of the shell (11).

2. A method for manufacturing a coupled inductor according to claim 1, characterized in that: The following steps are involved: S1: prefabricating a mold for a base block box (10) and a mold for a base block plug (20) according to the specifications and sizes of the base block box (10) and the base block plug (20), filling the corresponding molds with manganese-zinc ferrite powder and molding to obtain a base block box (10) and a base block plug (20) with improved molding density; S2: taking a conductive metal sheet according to the specifications of the primary coil (31) and the secondary coil (32), and bending the sheet into a shape; S3: spraying a layer of organic material on the surface of the formed primary coil (31) and the secondary coil (32) for insulation treatment; S4: The two main vertical coils (312) on the main coil (31) are respectively embedded in the two right side avoidance grooves (13) of the base block box (10), and then pushed downward until the main coil (31) abuts against the short stop column (14) in the base block box (10), and the two main horizontal coils (313) on the main coil (31) buckle the right side opening of the base block box (10); S5: The two secondary vertical coils (322) on the secondary coil (32) are respectively embedded in the two left avoidance grooves (13) of the base block box (10), and then pushed downward until the secondary coil (32) abuts against the long stop column (15) in the base block box (10), and the two secondary horizontal coils (323) on the secondary coil (32) buckle the left opening of the base block box (10); S6: Next, insert the base block column (22) in the base block plug (20) into the U-shaped grooves of the primary coil (31) and the secondary coil (32) until the base block cover (21) in the base block plug (20) abuts against the two primary horizontal coils (313) and the two secondary horizontal coils (323); S7: Finally, the base block box (10), the base block plug (20) and the coil assembly (30) are formed into one piece by hot pressing through a mold and a machine.

3. A coupled inductor and a method for manufacturing the same according to claim 2, characterized in that: In S7, the hot pressing temperature is 130-150°C; and / or the hot pressing pressure is 6.5-7.5 T / cm2; and / or the hot pressing time is 85-120s.

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