Coupling inductor, manufacturing method of coupling inductor and power supply

Abstract

The invention belongs to the technical field of inductance devices, and discloses a coupling inductor, a manufacturing method of the coupling inductor and a power supply. The coupling inductor comprises an E-shaped iron core structure, a coil assembly and an I-shaped iron core structure. The number of the E-shaped iron core structures is at least two, the at least two E-shaped iron core structures are arranged in a stacked mode, each E-shaped iron core structure comprises a magnetic core, each magnetic core is provided with a middle column in a protruding mode and two limiting bosses arranged on the two sides of the middle column in a spaced mode, and a containing space is formed by gaps between the middle columns and the limiting bosses; the coil assembly is contained in the containing space and comprises an inner coil and an outer coil, the inner coil sleeves and wraps the middle column, the outer coil sleeves the inner coil and is located between the two limiting bosses, and the bent ends of the inner coil and the outer coil are both exposed out of the containing space; and the I-shaped iron core structure is arranged on the top surface of the E-shaped iron core structure at the top. According to the coupling inductor, the voltage withstanding degree of the whole device is improved, grinding treatment is not needed, and short circuit is avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of inductor devices, and in particular to a coupled inductor, a method for manufacturing a coupled inductor, and a power supply. Background Art

[0002] Inductors are the most commonly used components in electronic devices and are widely used in various circuits to achieve the functions of filtering, energy storage, matching, and resonance. As electronic products become increasingly miniaturized and portable, and components are assembled with high density, inductor components have developed rapidly; and in consideration of electromagnetic compatibility, the ability of electronic products to resist electromagnetic interference has become a basic design requirement, which has increased the demand and application of inductors.

[0003] TLVR (Trans-Inductor Voltage Regulator) is a voltage regulator that uses the primary winding of a transformer as the output inductor. TLVR is an inductor component that can maintain voltage stability during transient load changes. Compared with traditional inductors, TLVR has the advantages of low loss, wide operating temperature range, fast transient response, and small size, and is suitable for low voltage and high current environments. At present, my country's TLVR inductor industry is still in its infancy and has a low market share.

[0004] The manufacturing process of the existing TLVR inductor structure generally includes: pressing the magnetic core; assembling the coil by glue dispensing; packaging and testing. When pressing the magnetic core, a mold is used to press the powder into a magnetic core of a certain shape; when assembling the coil by glue dispensing, glue is usually used to bond the coil and the magnetic core. The inductor performance obtained by this process flow is poor. Secondly, in the existing manufacturing process, it is necessary to hot-press and wrap the powder on the semi-finished products after the coil and the magnetic core are formed, so that the electrode is wrapped, and the electrode surface needs to be ground to make it exposed. During the grinding process, the powder particles will cause poor voltage resistance at the coil end, and this step adds a grinding process, making the overall process complicated. Summary of the invention

[0005] The object of the present invention is to provide a coupled inductor, a method for manufacturing a coupled inductor, and a power supply, which can effectively simplify the preparation process of the coupled inductor, improve the voltage resistance of the coupled inductor, and improve the reliability of use.

[0006] To achieve this object, the present invention adopts the following technical solutions:

[0007] A coupled inductor, comprising:

[0008] At least two E-shaped core structures are provided, and at least two of the E-shaped core structures are stacked. The E-shaped core structure includes a magnetic core, and the magnetic core is convexly provided with a middle column and two limiting bosses respectively arranged at intervals on both sides of the middle column, and the gap between the middle column and the limiting bosses forms an accommodating space;

[0009] A coil assembly is accommodated in the accommodation space, the coil assembly comprises an inner coil and an outer coil, the inner coil is sleeved and wrapped around the middle column, the outer coil is sleeved outside the inner coil and is located between the two limiting bosses, and the bent ends of the inner coil and the outer coil are exposed outside the accommodation space;

[0010] The I-shaped iron core structure is arranged on the top surface of the E-shaped iron core structure.

[0011] In some possible embodiments, the height of the middle column and the height of the limiting boss are both the same as the longitudinal height of the inner coil; or, the height of the middle column and the height of the limiting boss are the same, and the height of the middle column and the height of the limiting boss are both greater than the longitudinal height of the inner coil.

[0012] In some possible implementations, the height of the middle column is the same as the height of the limiting boss, and both the height of the middle column and the height of the limiting boss are greater than the longitudinal height of the inner coil, and the height difference is less than or equal to 0.2 mm.

[0013] In some possible embodiments, there are two E-shaped core structures, namely a first E-shaped core structure and a second E-shaped core structure, the second E-shaped core structure is arranged on the top surface of the first E-shaped core structure, the bottom surface of the first E-shaped core structure is a plane or a step structure, and the bottom surface of the second E-shaped core structure is a plane.

[0014] In some possible implementations, the bottom surface of the first E-shaped core structure is a step structure, the step surface of the step structure faces downward, and the step depth of the step structure is 0.5 mm-1.5 mm.

[0015] In some possible implementations, the gap between the inner coil and the middle column is 0.05 mm-0.2 mm;

[0016] And / or, the gap between the outer coil and the limiting boss is 0.05mm-0.2mm.

[0017] In some possible implementations, the I-shaped core structure is configured as a planar structure or a stepped structure.

[0018] The present invention also provides a power supply, comprising the coupled inductor as described in any of the above solutions.

[0019] The present invention also provides a method for manufacturing a coupled inductor, which is applied to the coupled inductor as described in any of the above solutions, and comprises the steps of:

[0020] Installing the coil assembly in the E-shaped core structure to form a first structure;

[0021] At least two of the first structures are stacked to form a second structure;

[0022] Placing the I-shaped core structure on the second structure to form a third structure;

[0023] The third structure is placed in an extrusion die for extrusion molding.

[0024] In some possible implementations, before installing the coil assembly in the E-shaped core structure, the E-shaped core structure and the I-shaped core structure need to be prepared first, and both the E-shaped core structure and the I-shaped core structure are prepared by a hot pressing process.

[0025] Beneficial effects of the present invention:

[0026] The coupled inductor provided by the present invention comprises at least two E-shaped core structures which are stacked, and the coil assembly is arranged in the E-shaped core structure. The stacked structure can effectively improve the molding density of the magnetic core and improve the pressure resistance of the entire device. The magnetic core is convexly provided with a middle column and two limiting bosses which are respectively arranged at two sides of the middle column at intervals. The inner coil is sleeved and wrapped on the middle column, and the outer coil is sleeved outside the inner coil and is located between the two limiting bosses. The middle column has a limiting effect on the inner coil, and the limiting boss has a limiting effect on the outer coil, so that the inner coil and the outer coil are prevented from falling off during molding, and the coplanarity can be ensured at the same time. The bent ends of the inner coil and the outer coil are exposed in the accommodating space, and no grinding process is required to avoid short circuit.

[0027] The present invention also provides a power supply, comprising the above-mentioned coupled inductor, and the power supply has high reliability in use.

[0028] The present invention also provides a method for manufacturing a coupled inductor, wherein the third structure is molded by an extrusion molding process without adding any powder, thereby simplifying the manufacturing process and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 is a three-dimensional view of a coupled inductor provided by the present invention;

[0030] Figure 2 is an exploded diagram of a coupled inductor provided by the present invention;

[0031] Figure 3is a partial structural schematic diagram of a coupled inductor provided by the present invention;

[0032] Figure 4 It is a partial structural schematic diagram of a first E-shaped iron core structure provided by the present invention;

[0033] Figure 5 It is a partial structural schematic diagram of the second E-shaped iron core structure provided by the present invention.

[0034] In the figure:

[0035] 100, E-shaped iron core structure; 110, magnetic core; 111, middle column; 112, limiting boss;

[0036] 200, coil assembly; 210, inner coil; 220, outer coil;

[0037] 300. I-shaped core structure.

[0038] 400. A first E-shaped core structure;

[0039] 500. A second E-shaped core structure. DETAILED DESCRIPTION

[0040] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0041] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0043] In the description of this embodiment, the terms "upper", "lower", "right", etc., directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0044] The present embodiment provides a coupled inductor, aiming to solve the problem that the coupled inductor prepared by the prior art has poor performance and complicated preparation process. The coupled inductor can effectively simplify the preparation process of the coupled inductor, improve the voltage resistance of the coupled inductor, and improve the reliability of use.

[0045] like Figures 1 to 5 As shown, the coupled inductor includes an E-shaped core structure 100, a coil assembly 200 and an I-shaped core structure 300. At least two E-shaped core structures 100 are provided, and at least two E-shaped core structures 100 are stacked. The E-shaped core structure 100 includes a magnetic core 110, and the magnetic core 110 is provided with a central column 111 and two limiting bosses 112 respectively arranged at intervals on both sides of the central column 111. The gap between the central column 111 and the limiting bosses 112 forms a receiving space; the coil assembly 200 is accommodated in the receiving space, and the coil assembly 200 includes an inner coil 210 and an outer coil 220. The inner coil 210 is sleeved and wrapped on the central column 111, and the outer coil 220 is sleeved outside the inner coil 210 and is located between the two limiting bosses 112. The bent ends of the inner coil 210 and the outer coil 220 are exposed in the receiving space; the I-shaped core structure 300 is arranged on the top surface of the E-shaped core structure 100 at the top.

[0046] The coupled inductor comprises at least two E-shaped core structures 100 which are stacked, and the coil assembly 200 is arranged in the E-shaped core structure 100. The stacked structure can effectively improve the molding density of the magnetic core 110 and improve the voltage resistance of the entire device. The magnetic core 110 is provided with a central column 111 and two limiting bosses 112 which are respectively arranged at intervals on both sides of the central column 111. The inner coil 210 is sleeved and wrapped on the central column 111, and the outer coil 220 is sleeved outside the inner coil 210 and is located between the two limiting bosses 112. The central column 111 limits the inner coil 210, and the limiting bosses 112 limit the outer coil 220, so as to prevent the inner coil 210 and the outer coil 220 from falling during molding, and at the same time ensure the coplanarity. The bent ends of the inner coil 210 and the outer coil 220 are exposed in the accommodation space, and no grinding process is required to avoid short circuit.

[0047] Optionally, the height of the middle column 111 and the height of the limiting boss 112 are the same as the longitudinal height of the inner coil 210; or, the height of the middle column 111 and the height of the limiting boss 112 are the same, and the height of the middle column 111 and the height of the limiting boss 112 are both greater than the longitudinal height of the inner coil 210. This arrangement can avoid damage to the insulating film of the inner coil 210 and the outer coil 220 during molding, thereby preventing the insulation from being reduced. In some embodiments, when the height of the middle column 111 and the height of the limiting boss 112 are the same, and the height of the middle column 111 and the height of the limiting boss 112 are both greater than the longitudinal height of the inner coil 210, the height difference is less than or equal to 0.2 mm.

[0048] In this embodiment, two E-shaped core structures 100 are provided, namely, a first E-shaped core structure 400 and a second E-shaped core structure 500. The second E-shaped core structure 500 is provided on the top surface of the first E-shaped core structure 400. The bottom surface of the first E-shaped core structure 400 is a plane or a step structure, and the bottom surface of the second E-shaped core structure 500 is a plane. For example, Figure 1 , Figure 2 and Figure 4 As shown, the bottom surface of the first E-shaped core structure 400 is set to a step structure, the step surface of the step structure faces downward, and the step depth of the step structure is 0.5mm-1.5mm. The setting of the step structure facilitates the positioning of the first E-shaped core structure 400. In other embodiments, the bottom surface of the first E-shaped core structure 400 can be set to other structures, such as a sloped structure, etc., which can be set as needed.

[0049] Optionally, the gap between the inner coil 210 and the middle column 111 is 0.05 mm-0.2 mm; and / or the gap between the outer coil 220 and the limiting boss 112 is 0.05 mm-0.2 mm. During the extrusion molding process of the coupled inductor, by setting the gap between the coil and the magnetic core 110, the coil is prevented from being damaged due to the inability to deform under the action of external force.

[0050] Optionally, the I-shaped core structure 300 is configured as a planar structure or a stepped structure. Figure 1 and Figure 2 As shown, the I-shaped core structure 300 is configured as a step-type structure, the step surface of the step-type structure is configured upward, and the bottom surface of the step-type structure is configured as a plane to increase the contact area between the I-shaped core structure 300 and the second E-shaped core structure 500 .

[0051] This embodiment also provides a power supply including the above-mentioned coupled inductor, and the power supply has high reliability in use.

[0052] This embodiment further provides a method for manufacturing a coupled inductor, which is applied to the above-mentioned coupled inductor and includes the following steps:

[0053] S1, installing the coil assembly 200 in the E-shaped core structure 100 to form a first structure;

[0054] S2, at least two first structures are stacked to form a second structure;

[0055] S3, placing the I-shaped core structure 300 on the second structure to form a third structure;

[0056] S4, placing the third structure in an extrusion die for extrusion molding.

[0057] In the method for manufacturing the coupled inductor, the third structure is molded by an extrusion molding process without adding any powder, thereby simplifying the manufacturing process and improving production efficiency.

[0058] Optionally, before installing the coil assembly 200 in the E-shaped core structure 100 , the E-shaped core structure 100 and the I-shaped core structure 300 need to be prepared first, and both the E-shaped core structure 100 and the I-shaped core structure 300 are prepared by a hot pressing process.

[0059] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A coupled inductor, characterized in that: include: At least two E-shaped iron core structures (100) are provided, and at least two of the E-shaped iron core structures (100) are stacked. The E-shaped iron core structure (100) comprises a magnetic core (110), and the magnetic core (110) is provided with a central column (111) and two limiting bosses (112) respectively arranged at intervals on both sides of the central column (111), and the gap between the central column (111) and the limiting bosses (112) forms a receiving space; A coil assembly (200) is accommodated in the accommodation space, the coil assembly (200) comprising an inner coil (210) and an outer coil (220), the inner coil (210) being sleeved and wrapped around the middle column (111), the outer coil (220) being sleeved outside the inner coil (210) and located between the two limiting bosses (112), and the bent ends of the inner coil (210) and the outer coil (220) being exposed outside the accommodation space; The I-shaped iron core structure (300) is arranged on the top surface of the E-shaped iron core structure (100).

2. The coupled inductor according to claim 1, wherein: The height of the middle column (111) and the height of the limiting boss (112) are both the same as the longitudinal height of the inner coil (210); or, the height of the middle column (111) and the height of the limiting boss (112) are the same, and the height of the middle column (111) and the height of the limiting boss (112) are both greater than the longitudinal height of the inner coil (210).

3. The coupled inductor according to claim 2, wherein: The height of the middle column (111) is the same as the height of the limiting boss (112), and both the height of the middle column (111) and the height of the limiting boss (112) are greater than the longitudinal height of the inner coil (210), and the height difference is less than or equal to 0.2 mm.

4. The coupled inductor according to claim 1, wherein: The E-shaped core structure (100) is provided with two, namely a first E-shaped core structure (400) and a second E-shaped core structure (500); the second E-shaped core structure (500) is provided on the top surface of the first E-shaped core structure (400); the bottom surface of the first E-shaped core structure (400) is a plane or a step structure; the bottom surface of the second E-shaped core structure (500) is a plane.

5. The coupled inductor according to claim 4, characterized in that: The bottom surface of the first E-shaped iron core structure (400) is a step structure, the step surface of the step structure faces downward, and the step depth of the step structure is 0.5 mm-1.5 mm.

6. The coupled inductor according to claim 1, wherein: The gap between the inner coil (210) and the middle column (111) is 0.05 mm to 0.2 mm; And / or, the gap between the outer coil (220) and the limiting boss (112) is 0.05 mm-0.2 mm.

7. The coupled inductor according to claim 1, wherein: The I-shaped iron core structure (300) is configured as a planar structure or a stepped structure.

8. A power supply, characterized in that: Comprising the coupled inductor according to any one of claims 1-7.

9. A method for manufacturing a coupled inductor, applied to the coupled inductor according to any one of claims 1 to 7, characterized in that: Includes steps: The coil assembly (200) is installed in the E-shaped iron core structure (100) to form a first structure; At least two of the first structures are stacked to form a second structure; Placing the I-shaped iron core structure (300) on the second structure to form a third structure; The third structure is placed in an extrusion die for extrusion molding.

10. The method for manufacturing a coupled inductor according to claim 9, characterized in that: Before installing the coil assembly (200) in the E-shaped iron core structure (100), the E-shaped iron core structure (100) and the I-shaped iron core structure (300) need to be prepared first, and the E-shaped iron core structure (100) and the I-shaped iron core structure (300) are both prepared by a hot pressing molding process.

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