Inductor

Abstract

The utility model relates to an inductor, which comprises a magnet and one or more groups of windings arranged in the magnet, and each group of windings comprises a main winding and an auxiliary winding; a through hole is formed in the magnet and penetrates through the first end face and the second end face of the magnet. The main winding and the auxiliary winding of each group of windings are assembled in the through holes; wherein each winding penetrates through the through hole and is arranged in the through hole of the formed magnet in a penetrating manner for assembly, and the two ends of each winding penetrate out of the through hole and are exposed out of the first end face and the second end face of the magnet respectively. After the magnet is formed, the winding is assembled, and the problem that the main winding and the auxiliary winding are conducted due to high-pressure forming is solved.

Description

TECHNICAL FIELD

[0001] The utility model relates to electronic components technical field especially an inductor. BACKGROUND

[0002] TLVR inductors have been widely used in server power supplies, data centers, high-performance integrated circuits, and other fields due to their fast transient response capabilities. In particular, in high-performance systems handling artificial intelligence, big data, and Internet of Things applications, TLVR inductors overcome the limitations of multi-phase devices and provide better power supply voltage regulation performance.

[0003] Global and Chinese TLVR coupled inductor market research shows that in the next few years, the market share of major manufacturers and regions will change, providing new opportunities for investors. Despite rapid market demand growth, China's TLVR inductor industry is still in its infancy, with a low market share and technology maturity that needs to be improved. This means that the current level of technology may not fully meet the needs of high-end applications.

[0004] Although TLVR inductors have advantages in reducing the number of back-end capacitors to reduce costs, they still face challenges in high costs in actual production and application. For example, existing TLVR inductors use magnetic powder and winding mold compression integrated molding, as the main winding and auxiliary winding have small spacing and are easy to conduct. SUMMARY

[0005] The technical problem to be solved by the utility model is to provide an inductor to solve the problem of high cost of existing inductors.

[0006] To solve the above technical problems, the utility model adopts the following technical scheme:

[0007] An inductor includes a magnet and one or more groups of windings installed in the magnet, each group of windings including a main winding and an auxiliary winding. The magnet has a through hole passing through the first end face and the second end face of the magnet. The main winding and the auxiliary winding of each group of windings are assembled in the through hole. Each winding passes through the through hole and is assembled in the through hole of the formed magnet, with both ends protruding out of the through hole and exposed to the first end face and the second end face of the magnet, respectively. Further, the main winding and the auxiliary winding are arranged in front of and behind each other with a predetermined overlap of the projection face. The main winding is an I-shaped winding, and the auxiliary winding is a U-shaped winding.

[0008] In some embodiments, the main winding and the auxiliary winding are arranged in front of and behind each other with a predetermined overlap of the projection face. The main winding is an I-shaped winding, and the auxiliary winding is a U-shaped winding.

[0009] In some embodiments, the two ends of the auxiliary winding are bent to form bent portions, and the length of the bent portions is greater than the corresponding length of the through hole.

[0010] In some embodiments, the inductor is a TLVR inductor, the main winding and the auxiliary winding are coupled to each other, the auxiliary winding has the same shape as the main winding but a different thickness, the thickness of the auxiliary winding is less than the thickness of the main winding, the magnet is an integrally formed magnet, the through hole is formed in the magnet synchronously, and the distance between the main winding and the auxiliary winding of the set of windings is 0.1-0.5 mm.

[0011] In some embodiments, the main winding and the auxiliary winding include conductors and insulating layers coated on the surfaces of the conductors, and first pads and second pads are arranged at the two ends of the windings respectively, the first pad of the main winding and the first pad of the auxiliary winding are located on the first end surface of the magnet and have a predetermined distance, the second pad of the main winding and the second pad of the auxiliary winding are located on the second end surface of the magnet and have a predetermined distance, the predetermined distance is the pad distance, and the pad distance is adjusted by changing the bending length or the bending direction of the two ends of the auxiliary winding or changing the area and position of the pads, so that the inductor is welded to an external circuit through the pads and short circuit is avoided.

[0012] In some embodiments, the area of the pad is a tin layer formed by immersion tinning after the insulating layer on the surface of the conductor is removed, the tin layer covers the surface of the conductor to form a conductive pad, and the first pad and the second pad of the auxiliary winding are arranged in directions away from the first pad and the second pad of the main winding respectively.

[0013] In some embodiments, the first end surface and the second end surface are two end surfaces of the magnet that face away from each other, wire outlet reserved grooves are arranged on the first end surface and the second end surface respectively, the bent portions of the two ends of the auxiliary winding are respectively laid in the wire outlet reserved grooves of the first end surface and the second end surface, the wire outlet reserved grooves are adapted to the bent portions of the auxiliary winding, the bent portions are laid in the wire outlet reserved grooves and cooperate with each other, and the bent portions and the wire outlet reserved grooves are bonded and fixed by a glue layer and / or are adapted to clamping cooperation.

[0014] In some embodiments, the auxiliary winding includes an intermediate portion and bent portions at the two ends, the intermediate portion of the auxiliary winding is assembled with the main winding in a front-to-back manner, the shapes of the auxiliary winding and the main winding are adapted to the shape of the through hole, and the auxiliary winding and the main winding are in close contact with the inner wall of the through hole and clamping cooperation, and the cross section of the through hole is a polygon.

[0015] The shapes of the set of main windings and auxiliary windings are adapted to the shape of the through hole and are assembled in the same through hole, the wire outlet reserved grooves on the first end surface and the second end surface are arranged at the edges of the through hole, and the wire outlet reserved grooves are in communication with the through hole.

[0016] The main winding is assembled close to the back of the auxiliary winding, so that the distance between the main winding and the auxiliary winding is close enough to obtain high coupling, and the main winding and the auxiliary winding are mutually insulated.

[0017] The main winding and the middle part of the auxiliary winding are mutually attached and the edges are aligned.

[0018] In some embodiments, the auxiliary winding and the main winding are fixed by adhesive layer bonding; the main winding and the auxiliary winding and the inner wall of the through hole are fixed by adhesive layer bonding.

[0019] In some embodiments, the surfaces of the main winding and the auxiliary winding opposite to each other are coated with adhesive layer, so that the main winding and the auxiliary winding are fixed by bonding; the surfaces of the auxiliary winding and the inner wall of the through hole mutually attached are coated with adhesive layer, so that the auxiliary winding and the inner wall of the through hole are fixed by bonding; the surfaces of the main winding and the inner wall of the through hole mutually attached are coated with adhesive layer, so that the main winding and the inner wall of the through hole are fixed by bonding.

[0020] The utility model discloses the beneficial effects are:

[0021] The magnet of the inductor is formed with a through hole to assemble the main winding and the auxiliary winding, avoids the problem that the main winding and the auxiliary winding are easily conducted when the winding and the magnetic powder are pressed by high pressure during the molding, reduces the manufacturing cost of the inductor, and the preparation of the magnet and the winding does not affect each other, so that the density of the magnet can be effectively improved, and the electromagnetic performance of the inductor is improved. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is the perspective view of the inductor of the utility model embodiment.

[0023] Figures 2-3 is the perspective view of the inductor of the utility model embodiment.

[0024] Figure 4 is the explosion view of the inductor of the utility model embodiment.

[0025] Figures 5-6 is the assembly process schematic view of the inductor of the utility model embodiment. DETAILED DESCRIPTION

[0026] Exemplary embodiments of the present application will be described herein below with reference to the accompanying drawings. While exemplary embodiments of the present application are shown in the drawings, it is understood that the present application can be embodied in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present application to those skilled in the art.

[0027] It is to be understood that the terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises", "comprising", "includes", "including" and "has" are inclusive and therefore specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order in which they are described unless specifically identified as an order dependent step. It is also to be understood that additional or alternative steps can be employed.

[0028] Although the terms first, second, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, an element, component, region, layer or section discussed below can be termed a second element, component, region, layer or section without departing from the teachings of example embodiments.

[0029] Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," "front," "rear," and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Such spatially relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" or "over" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0030] Please refer to Figures 1-6As shown, the utility model relates to a kind of inductor 100, including magnet 10 and the installation of one group or multiple groups of winding 20 in magnet 10.Inductor 100 can be TLVR inductance, each group of winding 20 includes main winding 21 and auxiliary winding 22, and main winding 21 and auxiliary winding 22 are mutually coupled.Magnet 10 is provided with through hole 11, through hole 11 penetrates the first end surface 12 and the second end surface 13 of magnet 10, and the main winding 21 and auxiliary winding 22 of each group of winding 20 are assembled in through hole 11.Each winding 20 penetrates through hole 11, and is assembled in the through hole 11 of magnet 10 formed, and two ends are exposed to the first end surface 12 and the second end surface 13 of magnet 10 respectively.

[0031] In the present application, the magnet 10 of inductor 100 is formed with through hole 11 inside to assemble main winding 21 and auxiliary winding 22 after forming, avoid winding 20 and magnetic powder together by pressing forming when main winding 21 and auxiliary winding 22 are easily conducted due to the required small spacing, to improve the yield of inductor 100, reduce the manufacturing cost of inductor 100.Magnet 10 and winding 20 between preparation do not affect each other, can also effectively improve the density of magnet 10, increase the electromagnetic performance of inductor 100.

[0032] As an embodiment, each group of winding 20 is installed in each through hole 11, and the main winding 21 and auxiliary winding 22 of each group of winding 20 are installed in the same through hole 11 of magnet 10 and are highly coupled between each other.The two ends of main winding 21 and auxiliary winding 22 are exposed to the first end surface 12 and the second end surface 13 of magnet 10 respectively and form solder pad;for electrically connected to external circuit.

[0033] Specifically, on the first end surface 12 of magnet 10, one end of main winding 21 forms first solder pad 211, and one end of auxiliary winding 22 forms first solder pad 221.On the other end surface, i.e., the second end surface 13 of magnet 10, the other end of main winding 21 forms second solder pad 212, and the other end of auxiliary winding 22 forms second solder pad 222.On the same end surface 12 or 13, the first solder pad 211 of main winding 21 and the first solder pad 221 of auxiliary winding 22 of the same group of winding 20 or the second solder pad 212 and 222 have a predetermined spacing.The predetermined spacing is the solder pad spacing 23.The setting of the solder pad spacing 23 ensures that the inductor 100 is not easy to short circuit or de-soldering when connected to the external circuit through the first solder pad 211 / 221 and the second solder pad 212 / 222.In actual application, the size of the first solder pad 221 and the second solder pad 222 of auxiliary winding 22, the solder pad spacing 23 can be flexibly adjusted, for example, by changing the different bending length and direction of auxiliary winding 22, adjusting the area and position of the first solder pad 212 and the second solder pad 222, etc., to facilitate the operation of inductor 100 soldered to the external circuit, to avoid short circuit, etc.

[0034] As an embodiment, the main winding 21 and the auxiliary winding 22 include an inner conductor and an insulating layer on the surface of the conductor, and a conductive pad is arranged at both ends of the main winding 21 and the auxiliary winding 22, so that the main winding 21 and the auxiliary winding 22 each form an insulated wire structure with a pad. For example, the manufacturing method of the pad includes: first removing the insulating layer of the area where the pad is pre-set at the end of the main winding 21 and the auxiliary winding 22 to expose the inner conductor, and then immersing the area where the insulating layer is removed in tin to form a tin layer on the surface of the conductor. Therefore, the pad area of the main winding 21 and the auxiliary winding 22 includes the inner conductor and the tin layer on the surface of the conductor, and the whole forms a conductive part, and the main winding 21 and the auxiliary winding 22 are electrically connected to the external circuit through the first pad 211 / 221 and the second pad 212 / 222. Therefore, the area of the main winding 21 and / or the auxiliary winding 22 except the pad includes the inner conductor and the insulating layer on the surface of the conductor, and the main winding 21 and the auxiliary winding 22 are close enough to each other and insulated from each other, and high coupling is formed inside the magnet. In some embodiments, the conductor inside the main winding 21 and the auxiliary winding 22 is copper.

[0035] As an embodiment, the main winding 21 is an I-shaped winding and is in the shape of a straight plate. For example, the I-shaped main winding 21 has a uniform thickness and a same cross section at each part, and the end faces of the two ends are flat. In the direction shown in the figure, corresponding to the length or height direction H, the main winding 21 penetrates through the through hole 11 of the magnet 10, and the two ends thereof extend out of the through hole 11 of the magnet 10 to the first end face 12 and the second end face 13 of the magnet 10, and the first pad 211 and the second pad 212 formed by the two end faces of the main winding 21 are exposed to the first end face 12 and the second end face 13, respectively. For example, the main winding 21 is a cuboid (not limited to a cuboid), and after the insulating layer on the surface of the inner conductor is removed and then immersed in tin, the first pad 211 and the second pad 212 are formed at the two end faces. In this embodiment, the I-shaped main winding 21 uses a copper wire, that is, the surface of the copper conductor is coated with an insulating layer. Of course, in other embodiments, the main winding 21 can be a bare copper wire, as long as the insulation of the main winding 21 and the auxiliary winding 22 is ensured in the subsequent process.

[0036] As an embodiment, the thickness d1 of the main winding 21 is relatively large, so the DCR is low. The thickness d2 of the auxiliary winding 22 is small, so the DCR is large, but the auxiliary winding 22 is easy to bend and the bending does not easily affect the outer insulating layer.

[0037] For example, the auxiliary winding 22 is a U-shaped winding, which includes a middle part 220 and two bent parts 223 and 224 at two ends. The middle part 220 is a straight plate, which is matched with the main winding 21. The auxiliary winding 22 is assembled with the main winding 21 in front and back positions and penetrates the same through hole 11 of the magnet 10. The thickness d2 of the auxiliary winding 22 is consistent, the cross section is the same, and each end surface is a plane. The middle part 220 of the auxiliary winding 22 is the same shape as the main winding 21, but the thickness is different, and is arranged in front and back alignment. For example, the auxiliary winding 22 (the middle part 220) and the main winding 21 are designed as a cuboid with different thicknesses d (d2 and d1) and other corresponding sizes. In the direction shown in the figure, along the length or height direction, the upper and lower ends of the auxiliary winding 22 are bent to form the bent parts 223 and 224 relative to the straight plate-shaped middle part. The first and second pads 221 and 222 provided on the outer surfaces of the two end bent parts 223 and 224 are respectively exposed to the opposite end surfaces 12 and 13 of the magnetic core 10.

[0038] In the U-shaped auxiliary winding 22, the length L2 of the two end bent parts 223 and 224 is greater than the length L1 of the through hole 11, and the auxiliary winding 22 can be smoothly assembled into the through hole 11 in the U-shaped state. This design can make the bent part 223 or the bent part 224 of the U-shaped winding pass through the through hole 11, further reduce the distance 23 between the main winding 21 and the auxiliary winding 22, and improve the inductance.

[0039] It should be noted that the size of the through hole 11 is related to the size and assembly method of the main winding 21 and the auxiliary winding 22, as long as the main winding 21 and the auxiliary winding 22 can be assembled into the through hole 11.

[0040] As an embodiment, the main winding 21 is assembled on the opposite surface (second surface) 226 of the middle part 220 of the auxiliary winding 22, which are close to each other and aligned; or, the main winding 21 is assembled on the same surface (first surface) 225 of the middle part 220 of the auxiliary winding 22, which are close to each other and aligned. Figures 1-2The front and back end surfaces of the magnetic core 10, i.e. the third end surface 15 and the corresponding projection surface of the opposite fourth end surface 16, have a predetermined degree of overlap in the projection surface when the main winding 21 is assembled on the opposite surface (second surface) 226 of the intermediate portion 220 of the auxiliary winding 22, so as to obtain high coupling. The surfaces of the main winding 21 and the intermediate portion 220 of the auxiliary winding 22 are insulated by an insulating layer, and thus are insulated from each other. The mutually adhering surfaces between the main winding 21 and the intermediate portion 220 of the auxiliary winding 22, i.e. the front surface (first surface) 215 of the main winding 21 and the opposite surface (second surface) 226 of the intermediate portion 220 of the auxiliary winding, are selected to be the surfaces with the largest area, for example, the largest rectangular surfaces, and the two surfaces 226 and 215 are adhered to each other in parallel in the front and back directions. The two end surfaces of the main winding can be made into pads in their entirety, or can be made into pads in part, and the shape and size of the pads can be adjusted as needed. The two ends of the auxiliary winding 22 are bent into bent portions 223 and 224 relative to the intermediate portion 220, and the bent directions are towards the front surface (first surface) 225 of the intermediate portion 220 and away from the assembly position of the main winding 21. The first pad 221 is made on the outer surface of the bent portion 223 close to the end thereof, and the second pad 222 is made on the outer surface of the bent portion 224 close to the end thereof, so as to increase the pad spacing 23 between the first pads 211 and 221 and the second pads 212 and 222 on the same side of the main winding 21 and the auxiliary winding 22. The bent portions 223 and 224 of the auxiliary winding 22 are respectively matched with the first end surface 12 and the second end surface 13 of the magnetic core 10. For example, the intermediate portion 220 of the auxiliary winding 22 is a straight plate, and is arranged vertically in the orientation shown in the figure, and the two ends are bent relative to the intermediate portion 220 to form horizontal (or other inclined) bent portions 223 and 224. In specific examples, the intermediate portion 220 is (but is not limited to) a cuboid, and the two end bent portions 223 and 224 are (but are not limited to) cubes or cuboids. The thickness d2 of the auxiliary winding 22 is less than the thickness d1 of the main winding 21.

[0041] The magnetic core 10 is provided with a corresponding number of through holes 11 corresponding to the number of groups of windings 20. In the orientation shown in the figure, the through holes 11 vertically (in the direction along the straight line H) pass through the first end surface 12 and the second end surface 13 of the magnetic core 10. The shape of the through holes 11 is matched with each group of windings 20. The height of the through holes 11 is matched with the height of the magnetic core 10 and the height of the main winding 21 and the auxiliary winding 22, and the cross-sectional shape of the through holes 11 is matched with the cross-sectional shape of the main winding 21 and the auxiliary winding 22 after assembly, so as to accommodate the main winding 21 and the auxiliary winding 22, so that the side end surfaces (not numbered) of the main winding 21 and the auxiliary winding 22 are adhered to the inner wall surfaces (not numbered) of the holes, the edges are matched, and the fit is clamped, and the spacing between the main winding 21 and the auxiliary winding 22 is small enough.

[0042] In the direction in which the main winding 21 and the auxiliary winding 22 are installed in front of and behind the through holes 11 (or the direction after the bent portions 223 and 224 of the auxiliary winding 22 are assembled), the length L1 (refer to FIG. 2) of the through holes 11 is greater than the length L2 (refer to FIG. 2) of the main winding 21 and the auxiliary winding 22. Figure 4The length L2 of the two end bending portions 223, 224 of the U-shaped auxiliary winding 22 is less than the length of the through hole 11, and the two end bending portions 223, 224 of the U-shaped winding can pass through the through hole 11 to be assembled, so that the distance between the main winding and the auxiliary winding can be further reduced to increase the inductance. For example, the cross section of the through hole 11 is rectangular, and the main winding 21 and the middle portion 220 of the auxiliary winding 22 are arranged close to each other to form a cuboid which is adapted to pass through the rectangular through hole 11. The second surface (back surface) 216 of the main winding 21 is adapted to be close to the rear inner wall surface of the through hole 11, and the main winding 21 and the through hole 11 are insulated from each other. The first surface (front surface) 225 of the middle portion 220 of the auxiliary winding 22 is adapted to be close to the front inner wall surface of the through hole 11, and the middle portion 220 of the auxiliary winding 22 and the through hole 11 are insulated from each other. The left and right side surfaces (not labeled) of the main winding 21 and the auxiliary winding 22 are adapted to be close to the left and right inner wall surfaces (not labeled) of the through hole 11, and the main winding 21, the auxiliary winding 22 and the through hole 11 are insulated from each other. The main winding 21 and the auxiliary winding 22 are aligned with each other in front and back directions, and the main winding 21 and the auxiliary winding 22 are insulated from each other.

[0043] In the preferred embodiment, the surfaces of the main winding 21 and the auxiliary winding 22 which are close to each other and the surfaces of the main winding 21 and the auxiliary winding 22 which are close to the inner wall of the through hole 11 are provided with a glue layer 24, so as to bond and fix the main winding 21 and the auxiliary winding 22 to each other and to bond and fix the main winding 21 and the auxiliary winding 22 to the inner wall of the through hole 11, so that the main winding 21 and the auxiliary winding 22 are fixed in the through hole 11. In addition, the main winding 21 and the auxiliary winding 22 are clamped in the through hole 11 by adapting the shape and size of the main winding 21 and the auxiliary winding 22 to the through hole 11, so that the main winding 21 and the auxiliary winding 22 are more stably installed in the through hole 11 of the magnet 10 and cannot move relative to each other.

[0044] Specifically, referring to Figure 4 The second surface (i.e. the back surface, the largest area end surface is shown) 216 of the main winding 21 is provided with a glue layer 24 between the second surface (i.e. the back surface, the largest area end surface is shown) 216 of the main winding 21 and the rear inner wall surface of the through hole 11, and the glue layer 24 is bonded and fixed after curing. Of course, in other embodiments, the glue layer 24 can also be provided between other end surfaces of the main winding 21 and the inner wall surface of the through hole 11. The first surface (i.e. the front surface, the largest area end surface is shown) 225 of the middle portion 220 of the auxiliary winding 22 is provided with a glue layer 24 between the first surface (i.e. the front surface, the largest area end surface is shown) 225 of the middle portion 220 of the auxiliary winding 22 and the front inner wall surface of the through hole 11, and the glue layer 24 is bonded and fixed after curing. Of course, in other embodiments, the glue layer 24 can also be provided between other end surfaces of the middle portion 220 and the inner wall surface of the through hole 11. The opposite surfaces 215, 226 of the main winding 21 and the middle portion 220 of the auxiliary winding 22 are provided with a glue layer 24, i.e. the first surface (front surface) 215 of the main winding 21 and / or the second surface (back surface) 226 of the middle portion 220 of the auxiliary winding 22 are coated with a glue layer 24, and the glue layer 24 is bonded and fixed after curing.

[0045] On the first end face 12 and the second end face 13 of the magnet 10, at both ends of the through hole 11, a wire outlet reserved slot 14 is arranged, which is a groove (not penetrating the two opposite end faces 12, 13 of the magnet) in communication with the through hole 11, and is adapted to the bending portions 223, 224 at both ends of the auxiliary winding 22, for example, a rectangular groove, used to flatly accommodate the bending portions 223, 224. After the auxiliary winding 22 penetrates the through hole 11 of the magnet 10, the bending portions 223, 224 at both ends of the auxiliary winding 22 extend into and flatly lie in the wire outlet reserved slot 14. The bending portions 223, 224 flatly lie in the wire outlet reserved slot 14 and can keep the end faces 12, 13 of the magnet flat or slightly protrude from the end faces 12, 13, and the first soldering pad 221 and the second soldering pad 222 made on the outer surface of the bending portions are exposed to the end faces 12, 13 of the magnet, so as to be welded to the external circuit.

[0046] The magnet 10 can be integrally compressed and formed by soft magnetic powder, and the through hole 11 with the wire outlet reserved slot 14 is formed at the same time of pressing the magnet 10. The shape of the magnet 10 can be trapezoidal, square, racetrack-shaped, etc., which can be selected according to specific applications. For example, the magnet 10 is trapezoidal. The magnet 10 has two opposite end faces, i.e., the first end face 12 and the second end face 13, which are flat and parallel to each other. Figures 1-2 In the shown orientation, the first end face 12 and the second end face 13 can be the upper surface and the lower surface of the magnet 10, which are trapezoidal in shape and parallel to each other. The distance between the two opposite end faces 12, 13, i.e., the thickness or height of the magnet 10, corresponds to the length or height of the windings 21, 22. One or more through holes 11 are synchronously formed in the magnet 10 for mounting one or more groups of windings 20 to form a single-phase or multi-phase inductor. In the figure, a two-phase inductor is taken as an example, and two groups of windings 20 are arranged in the magnet 10, which are connected to the external circuit and two auxiliary windings 22 in the two groups of windings 20 are connected in series. The third end face 15 and the fourth end face 16 are the front surface and the rear surface, which are rectangular in shape and parallel to each other.

[0047] For example, referring to Figures 5-6assembly process of the inductor is as follows: firstly, the surface of the U-shaped auxiliary winding 22 is glued, and the adhesive layer 24 can be coated only on the first surface (front surface) 225 of the middle part 220; secondly, the auxiliary winding 22 is inserted through the through hole 11 and abuts against one side (front side) in the through hole 11, so that the first surface 225 of the adhesive layer 24 is adhered to the corresponding inner wall surface (front inner wall surface) of the through hole 11, the bending parts 223 and 224 extend to the magnet end surfaces 12 and 13 respectively and are laid in the wire outlet reserved groove 14, the surfaces of the bending parts 223 and 224 which are in contact with the wire outlet reserved groove 14 can also be coated with the adhesive layer 24 to form an adhering and fixing structure, and the upper surfaces of the bending parts 223 and 224 are respectively provided with the first solder pad 221 and the second solder pad 222, and the first solder pad 221 and the second solder pad 222 are respectively arranged close to the end edges of the bending parts 223 and 224. Then, the surfaces of the main winding 21 and the auxiliary winding 22 which are in contact with the inner wall of the through hole 11 are coated with the adhesive layer 24, for example, the first surface (front surface) 215 and the second surface (back surface) 216 of the main winding 21 are coated with the adhesive layer 24, and after the two surfaces are glued, the main winding 21 is directly inserted into the through hole 11 close to the other side, for example, the rear side, so that the front surface 215 of the main winding 21 is adhered and fixedly arranged on the back surface 226 of the auxiliary winding 22, and the back surface 216 of the main winding 21 is adhered and fixedly arranged with the rear inner wall surface of the through hole 11. The main winding 21 is inserted through the through hole 11, and the main winding 21, the auxiliary winding 22 and the inner wall of the through hole 11 form an adhering and fixing structure, that is, the assembly is completed, and after the adhesive layer 24 is solidified, the main winding 21 and the auxiliary winding 22 are firmly adhered in the through hole 11, and the main winding 21, the auxiliary winding 22 and the through hole 11 are tightly fitted. In other embodiments, the auxiliary winding 22 is L-shaped with one end bent or straight before assembly, is inserted through the through hole 11, and finally the other end is bent or both ends are bent to form a U-shaped winding. It can be understood that, compared with directly assembling the U-shaped auxiliary winding 22, the auxiliary winding 22 is bent after assembly, which can avoid subsequent bending on the magnet 10.

[0048] For example, the first solder pad 211 of the main winding 21 and the first solder pad 221 of the auxiliary winding 22 are located in the same plane and on the first end surface 12 of the magnet 10, and the second solder pad 212 of the main winding 21 and the second solder pad 222 of the auxiliary winding 22 are located in the same plane and on the second end surface 13 of the magnet 10. By controlling the size of the area of the insulating layer removed from the two ends of the U-shaped auxiliary winding 22, the size of the solder pad spacing 23 between the first solder pads 221 and 221 or between the second solder pads 212 and 222 of the main winding 21 and the auxiliary winding 22 can be appropriately increased, so as to reduce the risk of welding conduction between the main winding 21 and the auxiliary winding 22.

[0049] The inductor 100 of the utility model, when making, first, the auxiliary winding 22 is pasted on the inner wall of the through hole 11 in the magnet 10 and the bending part 223, 224 at both ends extends into the outlet reserved slot 14, can be clamped and combined and pasted fixed, then, the main winding 21 is glued and assembled behind the auxiliary winding 22. One or more groups of windings 20 and the assembly of the magnet 10 are not integrated with the soft magnetic powder, therefore, the problem that the main and auxiliary windings 21, 22 are easy to conduct because of small spacing when the winding 20 and the magnet 10 are integrated and pressed together can be avoided. In the above embodiment, the magnet 10 is integrated with the soft magnetic powder by hot pressing or the through hole 11 and the outlet reserved slot 14 are formed in the magnet 10 synchronously, then, the winding 20 is assembled in the through hole 11 through another process.

[0050] The inductor 100 of the utility model, the magnet 10 is directly made with the through hole 11 and the outlet reserved slot 14, and the main winding 21 is set as I shape, the auxiliary winding 22 is set as U shape, and the main and auxiliary windings 21, 22 are assembled in the through hole 11 of the formed magnet 10. Therefore, the magnet 10 without assembling the winding can be formed under higher pressure, and the insulating layer of the winding 21, 22 is not affected. The spacing of the main winding 21 and the auxiliary winding 22 can be between 0.1-0.5mm, ensuring that the product meets the high coupling requirement; the both sides of the U-shaped winding are controlled by removing the area size of the insulating layer, and the welding conduction risk between the main winding 21 and the auxiliary winding 22 can be reduced by appropriately increasing the pad spacing 23.

[0051] Although the embodiments of the utility model have been shown and described, it can be understood by those skilled in the art that various changes, modifications, replacements and variations can be made to these embodiments without departing from the principles and spirits of the utility model, and the protection scope of the utility model is defined by the appended claims and their equivalent scope.

Claims

1. An inductor comprising a magnetic body and one or more sets of windings mounted within the magnetic body, each set of windings comprising a primary winding and a secondary winding; characterized by: The magnet is provided with a through hole penetrating the first end surface and the second end surface of the magnet; the main winding and the auxiliary winding of each group of windings are assembled in the through hole; wherein each winding penetrates the through hole, is assembled in the through hole of the formed magnet, and the two ends thereof are exposed to the first end surface and the second end surface of the magnet respectively.

2. The inductor of claim 1, wherein: The main winding and the auxiliary winding are arranged in front and back and have a predetermined overlap of projection surface; the main winding is an I-shaped winding, and the auxiliary winding is a U-shaped winding.

3. The inductor of claim 2, wherein: The two ends of the auxiliary winding are bent to form a bent portion, and the length of the bent portion is greater than the corresponding length of the through hole.

4. The inductor of claim 1, wherein: The inductor is a TLVR inductor, and the main winding and the auxiliary winding are mutually coupled; the auxiliary winding has the same shape as the main winding but different thickness; the thickness of the auxiliary winding is less than that of the main winding; The magnet is an integrally formed magnet; the through hole is synchronously formed in the magnet; the spacing between the main winding and the auxiliary winding of the group of windings is 0.1-0.5 mm.

5. The inductor of claim 1, wherein: The main winding and the auxiliary winding comprise a conductor and an insulating layer coated on the surface of the conductor, and first and second pads are arranged at the two ends of the winding respectively; the first pad of the main winding and the first pad of the auxiliary winding are located on the first end surface of the magnet and have a predetermined spacing, and the second pad of the main winding and the second pad of the auxiliary winding are located on the second end surface of the magnet and have a predetermined spacing; the predetermined spacing is the pad spacing; by changing the bending length or bending direction of the two ends of the auxiliary winding, or changing the area and position of the pad, the pad spacing is adjusted, so that the inductor is welded to an external circuit through the pad and short circuit is avoided.

6. The inductor of claim 5, wherein: The area of the pad is a tin layer formed by immersing tin after removing the insulating layer on the surface of the conductor, and the tin layer covers the surface of the conductor to form a conductive pad; the first pad and the second pad of the auxiliary winding are arranged in directions away from the first pad and the second pad of the main winding respectively.

7. The inductor of claim 1, wherein: The first end surface and the second end surface are two end surfaces of the magnet facing away from each other, and wire outlet reserved slots are arranged on the first end surface and the second end surface respectively; the bent portions of the two ends of the auxiliary winding are respectively laid in the wire outlet reserved slots on the first end surface and the second end surface; the wire outlet reserved slots are adapted to the bent portions of the auxiliary winding, the bent portions are laid in the wire outlet reserved slots and cooperate with each other; the bent portions and the wire outlet reserved slots are bonded and fixed by a glue layer and / or adaptively clamped.

8. The inductor of claim 7, wherein: The auxiliary winding comprises an intermediate portion and bent portions at the two ends, and the intermediate portion of the auxiliary winding is assembled in front of and behind the main winding; the shapes of the auxiliary winding and the main winding are adapted to the shape of the through hole, and the auxiliary winding and the main winding are in close contact with the inner wall of the through hole and are clamped; the cross section of the through hole is polygonal; The shapes of the main winding and the auxiliary winding are adapted to the shape of the through hole and are assembled in the same through hole; the wire outlet reserved slots on the first end surface and the second end surface are arranged at the edges of the through hole, and the wire outlet reserved slots are in communication with the through hole; The main winding is assembled on the back of the auxiliary winding to make the distance between the main winding and the auxiliary winding close enough to obtain high coupling, and the main winding and the auxiliary winding are insulated from each other; The main winding and the middle part of the auxiliary winding are in close contact and the edges are aligned.

9. The inductor of any one of claims 1-8, wherein: The auxiliary winding and the main winding are fixed by adhesive layer; the main winding and the auxiliary winding and the inner wall of the through hole are fixed by adhesive layer.

10. The inductor of claim 9, wherein: The opposite surfaces of the main winding and the auxiliary winding are coated with adhesive layer to form adhesive fixing between the main winding and the auxiliary winding; the surfaces of the auxiliary winding and the inner wall of the through hole in close contact are coated with adhesive layer to form adhesive fixing between the auxiliary winding and the inner wall of the through hole; the surfaces of the main winding and the inner wall of the through hole in close contact are coated with adhesive layer to form adhesive fixing between the main winding and the inner wall of the through hole. The opposite surfaces of the main winding and the auxiliary winding are coated with adhesive layer to form adhesive fixing between the main winding and the auxiliary winding; the surfaces of the auxiliary winding and the inner wall of the through hole in close contact are coated with adhesive layer to form adhesive fixing between the auxiliary winding and the inner wall of the through hole; the surfaces of the main winding and the inner wall of the through hole in close contact are coated with adhesive layer to form adhesive fixing between the main winding and the inner wall of the through hole.

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