Inductor

Abstract

The invention relates to the technical field of inductors, a magnet yoke column of the inductor is arranged on one side of a first magnetic core column in a third direction, a magnetic path between the magnet yoke column and the first magnetic core column and a magnetic path between the magnet yoke column and a second magnetic core column are conducted through an end magnet yoke, and the first magnetic core column and the second magnetic core column are arranged in the first direction. The first direction is perpendicular to the third direction, so that in the first direction, namely the width direction of the inductor, the size of the inductor is reduced, the overall size of the inductor is more compact, and the inductor can be better suitable for occasions where the width size of the inductor is smaller. In addition, after the magnet yoke columns are arranged side by side, the magnetic flux area can be increased in a limited space.

Description

Technical Field

[0001] The invention relates to the technical field of inductors, and in particular to an inductor with a yoke column placed beside it. Background Art

[0002] The on-board high-power inductor is used in the power supply system of the car. The current boost inductor usually includes two inductor coils, a magnetic core column and a yoke column, wherein the magnetic core column is in the inductor coil and the yoke column is outside the inductor coil. The yoke column of the current inductor is usually arranged between the two magnetic core columns, which will result in a larger size between the two magnetic core columns of the inductor, making the width of the inductor body larger, and poor adaptability to occasions requiring a smaller width of the inductor body. Summary of the invention

[0003] The present invention provides an inductor which can be better applied to the occasions requiring a smaller width dimension of the inductor body.

[0004] In a first aspect, an embodiment provides an inductor, comprising a first inductor coil, a second inductor coil, a first magnetic core column, a second magnetic core column, a yoke column and an end yoke; the first inductor coil is sleeved on the periphery of the first magnetic core column and a first insulator is filled between the two, the second inductor coil is sleeved on the periphery of the second magnetic core column and a second insulator is filled between the two, the end yoke is at the end of the yoke column, and the magnetic path between the yoke column and the first magnetic core column and the magnetic path between the yoke column and the second magnetic core column are both conducted through the end yoke;

[0005] The first magnetic core column and the second magnetic core column are arranged in a first direction, the first magnetic core column, the second magnetic core column and the yoke column all extend along the second direction, and the first direction is perpendicular to the second direction; the first direction and the second direction are both perpendicular to a third direction, and the yoke column is arranged on one side of the first magnetic core column in the third direction.

[0006] Furthermore, in one embodiment, the end of the first magnetic core column, the end of the second magnetic core column and the end of the yoke column are all magnetically conductive with the end yoke; the end yoke includes a first magnetic core column conductive surface that is magnetically conductive with the first magnetic core column, a second magnetic core column conductive surface that is magnetically conductive with the second magnetic core column and a yoke column conductive surface that is magnetically conductive with the yoke column, the first magnetic core column conductive surface is perpendicular to the yoke column conductive surface, and the first magnetic core column conductive surface and the second magnetic core column conductive surface are both on one side of the end yoke in the second direction.

[0007] Furthermore, in one embodiment, the inductor includes a yoke column insulator, the yoke column insulator is covered on the yoke column, and the side of the first inductor coil facing the yoke column and the side of the second inductor coil facing the yoke column are both in contact with the yoke column insulator.

[0008] Furthermore, in one embodiment, the side surface of the first inductor coil facing away from the yoke column and the side surface of the second inductor coil facing away from the yoke column are both exposed heat dissipation surfaces, and the heat dissipation surfaces are used to fit with a thermal pad for heat dissipation.

[0009] Furthermore, in one embodiment, the inductor includes an inductor insulator, which fixes the yoke column, the end yoke, the first magnetic core column and the second magnetic core column, and the inductor insulator includes an extrusion protrusion protruding toward the third direction, and the extrusion protrusion is arranged on the periphery of the heat dissipation surface to squeeze the thermal pad to cause the thermal pad to be recessed.

[0010] Furthermore, in one embodiment, the yoke column is in the shape of a flat plate.

[0011] Furthermore, in one embodiment, the yoke column includes a first column and a second column, the first column and the second column are arranged along a first direction, the first column and the second column are in contact with each other, or the first column and the second column are arranged at intervals along the first direction and form a column gap, and the inductor includes an inductor lead, and at least one of the inductor leads and / or the terminal of the first inductor coil and / or the terminal of the second inductor coil passes through the column gap.

[0012] Furthermore, in one embodiment, the inductor is a magnetically integrated staggered parallel inductor, and the first inductor coil and the second inductor coil are connected in parallel.

[0013] Furthermore, in one embodiment, the inductor includes a first inductor insulator and a second inductor insulator, the first inductor insulator and the second inductor insulator are arranged at intervals in the extension direction of the yoke column, at least one of the end yokes is a first yoke magnetically connected to one end of the yoke column, and at least one of the end yokes is a second yoke magnetically connected to the other end of the yoke column; the first inductor insulator fixes one end of the yoke column to the first yoke, and the second inductor insulator fixes the other end of the yoke column to the second yoke.

[0014] Furthermore, in one embodiment, the first inductor insulator includes a surface portion covering the outer surface of the first magnetic yoke and an inner portion located on the side of the first magnetic yoke facing the first magnetic core column, and the inner portion is connected to the surface portion; in the extension direction of the first magnetic core column, at least a portion of the inner portion is located between the first insulator and the end magnetic yoke.

[0015] According to the inductor of the above embodiment, the yoke column of the inductor is arranged on one side of the first magnetic core column in the third direction, the magnetic path between the yoke column and the first magnetic core column, and the magnetic path between the yoke column and the second magnetic core column are both conducted through the end yoke, the first magnetic core column and the second magnetic core column are arranged along the first direction, and the first direction is perpendicular to the third direction, so that in the first direction, i.e., the width direction of the inductor, the width dimension of the inductor body is reduced, the overall dimension of the inductor is more compact, and it can better adapt to occasions with a smaller width dimension of the inductor. In addition, after the yoke column is placed aside, the magnetic flux area can be increased in a limited space. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a schematic structural diagram of an inductor in an embodiment;

[0017] Figure 2 is another structural schematic diagram of an inductor in an embodiment;

[0018] Figure 3 It is a schematic diagram of a structure in which an inductor and a thermal pad are assembled together in one embodiment;

[0019] Figure 4 is a cross-sectional view of an inductor in one embodiment;

[0020] Figure 5 is another cross-sectional view of an inductor in one embodiment;

[0021] Figure 6 is a cross-sectional view of an inductor from another perspective in an embodiment;

[0022] Figure 7 is a schematic structural diagram of an inductor in an embodiment after the inductor insulator is hidden;

[0023] Figure 8 is another structural schematic diagram of an inductor in an embodiment after the inductor insulator is hidden;

[0024] Fig. 9 A schematic diagram of the structure of a yoke column assembly in an embodiment;

[0025] Fig.10 An exploded view of a first assembly, a second assembly and a pre-positioning member in an embodiment;

[0026] Fig.11 is a schematic structural diagram of a first inductor insulator in an embodiment;

[0027] Fig.12 A schematic diagram of the structure of a yoke column and an end yoke in an embodiment;

[0028] Fig.13 FIG. 4 is a schematic diagram of the structure of another inductor in an embodiment.

[0029] List of feature names corresponding to the reference numerals in the figure: 1. first assembly; 11. first inductor coil; 12. first magnetic core column; 121. magnetic core block; 122. ceramic sheet; 13. first insulator; 2. yoke column assembly; 21. yoke column; 211. first column; 212. second column; 213. column interval; 22. yoke column insulator; 221. first positioning structure; 2211. first positioning groove; 222. second positioning structure; 2221. second positioning groove; 3. inductor insulator; 31. first inductor insulator; 311. surface portion; 312. inner portion; 3121. first inner portion; 31 22. Second inner portion; 32. Second inductor insulator; 33. Extrusion protrusion; 321. Conductive row injection molding portion; 4. End yoke; 41. First magnetic core column conductive surface; 42. Second magnetic core column conductive surface; 43. Yoke column conductive surface; 5. Second assembly; 51. Second inductor coil; 52. Second magnetic core column; 53. Second insulator; 6. Inductor lead; 61. Wiring conductive row; 611. First wiring conductive row; 7. Mounting insert; 71. Mounting hole; 8. Thermal pad; 10. Pre-positioning member; 101. Protrusion; 102. Positioning hole; 103. Inductor copper row; 1031. Input terminal; 1032. Output terminal.

[0030] Explanation on the reference numerals in brackets in the drawings: In the reference numerals in brackets in the drawings, the features referred to by the reference numerals are both the features represented by the numbers in the brackets and the features represented by the numbers outside the brackets. DETAILED DESCRIPTION

[0031] The present invention is further described in detail below by specific embodiments in conjunction with the accompanying drawings. Wherein similar elements in different embodiments adopt associated similar element numbers. In the following embodiments, many detailed descriptions are for making the present application better understood. However, those skilled in the art can easily recognize that some features can be omitted in different situations, or can be replaced by other elements, materials, methods. In some cases, some operations related to the present application are not shown or described in the specification, this is to avoid the core part of the present application being overwhelmed by too much description, and for those skilled in the art, it is not necessary to describe these related operations in detail, and they can fully understand the related operations according to the description in the specification and the general technical knowledge in the art.

[0032] In addition, the features, operations or characteristics described in the specification can be combined in any appropriate manner to form various implementations. At the same time, the steps or actions in the method description can also be interchanged or adjusted in a manner that is obvious to those skilled in the art. Therefore, the various sequences in the specification and the drawings are only for the purpose of clearly describing a certain embodiment and are not meant to be a required sequence, unless otherwise specified that a certain sequence must be followed.

[0033] The serial numbers of the components in this document, such as "first", "second", etc., are only used to distinguish the objects described and do not have any order or technical meaning. The "connection" and "coupling" mentioned in this application, unless otherwise specified, include direct and indirect connections (couplings).

[0034] In one embodiment, please refer to Figures 1 to 12 The inductor includes a first inductor coil 11 , a second inductor coil 51 , a first magnetic core column 12 , a second magnetic core column 52 , a yoke column 21 and an end yoke 4 .

[0035] The first inductor 11 is sleeved around the first magnetic core 12 and a first insulator 13 is filled between the two. The second inductor 51 is sleeved around the second magnetic core 52 and a second insulator 53 is filled between the two. Figures 1 to 6 , the first inductor 11 is sleeved around the periphery of the first magnetic core column 12, and a gap is left between the first inductor 11 and the first magnetic core column 12. The first insulator 13 fixes the first inductor 11 and the first magnetic core column 12. At least a portion of the first insulator 13 fills the gap between the first inductor 11 and the first magnetic core column 12. The second inductor 51 is sleeved around the periphery of the second magnetic core column 52, the second insulator 53 fixes the second inductor 51 and the second magnetic core column 52, and at least a portion of the second insulator 53 fills the gap between the second inductor 51 and the second magnetic core column 52.

[0036] The end yoke 4 is located at the end of the yoke column 21, and the magnetic path between the yoke column 21 and the first magnetic core column 12, and the magnetic path between the yoke column 21 and the second magnetic core column 52 are both conducted through the end yoke 4. It should be noted that the yoke column 21 and the end yoke 4 are both located outside the first inductor 11 and in the second inductor 51, playing the role of conducting the magnetic path.

[0037] The first magnetic core column 12 and the second magnetic core column 52 are arranged in the first direction, the first magnetic core column 12, the second magnetic core column 52 and the yoke column 21 all extend in the second direction, and the first direction is perpendicular to the second direction. The first direction and the second direction are both perpendicular to the third direction, and the yoke column 21 is arranged on one side of the first magnetic core column 12 in the third direction.

[0038] The yoke column 21 of the inductor is arranged on one side of the first magnetic core column 12 in the third direction, that is, the yoke column 21 is arranged in a side-by-side manner, and the magnetic paths between the yoke column 21 and the first magnetic core column 12 and the magnetic paths between the yoke column 21 and the second magnetic core column 52 are both conducted through the end yoke 4, and the first magnetic core column 12 and the second magnetic core column 52 are arranged along the first direction, and the first direction is perpendicular to the third direction, so that in the first direction, that is, the width direction of the inductor, the width dimension of the inductor body is reduced, and the overall dimension of the inductor is more compact, which can better adapt to occasions with a smaller width dimension of the inductor. In addition, after the yoke column 21 is placed aside, the magnetic flux area can be increased in a limited space. The width dimension of the inductor body is the space dimension occupied by the first magnetic core column 12 and the second magnetic core column 52 in the first direction. The dimension of the yoke column 21 in the first direction is smaller than the space dimension occupied by the first magnetic core column 12 and the second magnetic core column 52 in the first direction.

[0039] In one embodiment, the first inductor 11 and the second inductor 51 are connected in parallel, and the inductor is a magnetically integrated staggered parallel inductor, which is smaller in size and weight than two single inductors after magnetic integration.

[0040] In one embodiment, the yoke column 21 is arranged in a side-by-side manner, and magnetic paths are formed between the yoke column 21 and the first magnetic core column 12, between the yoke column 21 and the second magnetic core column 52, and between the first magnetic core column 12 and the second magnetic core column 52, so that the inductor forms a three-dimensional magnetic path in a three-dimensional space.

[0041] Specifically, in one embodiment, please refer to Figure 4 , the first insulator 13 is completely filled in the gap between the first inductor 11 and the first magnetic core column 12. In one embodiment, please refer to Figure 4The first insulator 13 partially fills the gap between the first inductor 11 and the first magnetic core 12, and partially extends on the portion of the first magnetic core 12 extending out of the first inductor 11. In another embodiment, the first insulator 13 may also extend to the outer surface of the first inductor 11 to cover at least a portion of the outer surface of the first inductor 11.

[0042] In one embodiment, please refer to Figures 1 to 6 The inductor includes an inductor insulator 3, and the inductor insulator 3 fixes the yoke column 21, the end yoke 4, the first magnetic core column 12 and the second magnetic core column 52. Specifically, the inductor insulator 3 is injection molded. In some other embodiments, the inductor insulator 3 can also be molded after the potting glue is cured, or firstly injection molded and then assembled with other parts.

[0043] In one embodiment, please refer to Figure 6 The inductor includes a yoke column insulator 22, and the yoke column insulator 22 is covered on the yoke column 21. Specifically, in one embodiment, the yoke column insulator 22 is injection molded on the yoke column 21.

[0044] The first insulator 13 , the yoke column insulator 22 , and the inductor insulator 3 may all be made of any feasible material. Usually, the first insulator 13 , the yoke column insulator 22 , and the inductor insulator 3 are all made of insulating materials.

[0045] The insulator involved in the present application can be formed in any feasible way, such as injection molding, potting molding, and the insulator can be directly molded together with other parts by injection molding, or it can be pre-injection molded and then assembled together with other parts if permitted.

[0046] Regarding the first magnetic core column 12, in one embodiment, please refer to Figure 4 and Figure 6 The first magnetic core column 12 includes at least two stacked magnetic core blocks 121, and there is a ceramic sheet 122 between adjacent magnetic core blocks 121. Specifically, in one embodiment, the number of magnetic core blocks 121 is four, and the number of ceramic sheets 122 is three, wherein the ceramic sheets 122 are made of magnetically conductive ceramics.

[0047] Further, in one embodiment, please refer to Figures 4 to 6, the end of the first magnetic core column 12, the end of the second magnetic core column 52 and the end of the yoke column 21 are all magnetically conductive with the end magnetic yoke 4. The end magnetic yoke 4 includes a first magnetic core column conductive surface 41, a second magnetic core column conductive surface 42 and a yoke column conductive surface 43. The first magnetic core column conductive surface 41 is perpendicular to the yoke column conductive surface 43. The first magnetic core column conductive surface 41 and the second magnetic core column conductive surface 42 are located on one side of the end magnetic yoke 4 in the second direction. In this way, the end magnetic yoke 4 is respectively attached to the magnetic core column and the yoke column 21 through different side surfaces, so that the end magnetic yoke 4 can be tightly attached to the yoke column 21 and the magnetic core column at the same time.

[0048] Further, in one embodiment, please refer to Figure 1 and Figure 6 The side surface of the first inductor 11 facing the yoke column 21 and the side surface of the second inductor 51 facing the yoke column 21 are both in contact with the yoke column insulator 22 .

[0049] Further, in one embodiment, please refer to Figure 3 and Figure 6 The side surface of the first inductor 11 facing away from the yoke column 21 and the side surface of the second inductor 51 facing away from the yoke column 21 are both exposed heat dissipation surfaces, and the heat dissipation surfaces are used to fit with the thermal pad for heat dissipation.

[0050] In this way, the side of the first inductor 11 that is in contact with the yoke column insulator 22 can dissipate heat through the yoke column 21, and the side of the first inductor 11 that is away from the yoke column 21 can dissipate heat through the thermal pad 8. Similarly, the second inductor 51 can also dissipate heat through the yoke column insulator 22 and the thermal pad 8, so that the inductor has better heat dissipation performance.

[0051] Further, in one embodiment, please refer to Figures 1 to 3 The inductor insulator 3 includes an extrusion protrusion 33 protruding toward the third direction. The extrusion protrusion 33 is arranged at the periphery of the heat dissipation surface to press the thermal pad to make the thermal pad concave.

[0052] In one embodiment, please refer to Figures 1 to 3 In order to ensure the stability of the relative position between the thermal pad 8 and the coil, the inductor insulator 3 has an extrusion protrusion 33. After the coil contacts the thermal pad 8, the extrusion protrusion 33 squeezes the thermal pad 8 to form a depression on the thermal pad 8. The extrusion protrusion 33 extends into the depression, which can limit the movement of the thermal pad 8, thereby preventing the thermal pad 8 from moving relative to the coil.

[0053] Further, in one embodiment, please refer to Figures 8 to 9 The yoke column 21 is in a flat plate shape. This is beneficial to reducing the thickness of the yoke column 21 and the volume of the inductor, and is also beneficial to increasing the heat dissipation area, so that the heat can be quickly dissipated after being conducted to the yoke column 21.

[0054] Further, in one embodiment, please refer to Figure 2 and Figure 6 The inductor insulator 3 includes a first inductor insulator 31 and a second inductor insulator 32. The first inductor insulator 31 and the second inductor insulator 32 are arranged at intervals in the extension direction of the yoke column 21. At least one end yoke 4 is a first yoke magnetically connected to one end of the yoke column 21, and at least one end yoke 4 is a second yoke magnetically connected to the other end of the yoke column 21. The first inductor insulator 3 fixes one end of the yoke column 21 to the first yoke, and the second inductor insulator 3 fixes the other end of the yoke column 21 to the second yoke. In this way, the inductor insulator 3 has a smaller coverage area, which can make the coil exposed to a larger area, so that the inductor has better heat dissipation performance.

[0055] Further, in one embodiment, please refer to Figure 6 The first inductor insulator 31 is injection molded at one end of the yoke column 21 , and the second inductor insulator 32 is injection molded at the other end of the yoke column 21 .

[0056] In one embodiment, please refer to Figure 1 and Figure 2 , the wiring conductive bar 61 of the inductor is led out from the first inductor insulator 31 and the second inductor insulator 32, so that the side of the yoke column insulator 22 facing away from the first inductor coil 11 is a plane that can contact the thermal pad 8, and at the same time, the side of the first inductor coil 11 facing away from the yoke column 21 and the side of the second inductor coil 51 facing away from the yoke column 21 are both planes that can contact the thermal pad 8. The inductor can use two parallel thermal pads 8 for heat dissipation, and the heat dissipation capacity is better. Of course, the heat dissipation surface that can contact the thermal pad 8 described in this application can also dissipate heat outward without using the thermal pad 8.

[0057] In one embodiment, please refer to Fig.12 The yoke column 21 includes a first column 211 and a second column 212 , and the first column 211 and the second column 212 are arranged along a first direction.

[0058] In one embodiment, please refer to Fig.12, the first column 211 and the second column 212 are arranged at intervals in the first direction, and a column interval 213 is formed between the first column 211 and the second column 212, the inductor includes an inductor lead 6, and at least one inductor lead 6 and / or a terminal of the first inductor coil 11 and / or a terminal of the second inductor coil 51 passes through the column interval 213. The column interval 213 can facilitate routing, and the yoke column 21 can be arranged on the same side of the first magnetic core column 12 and the second magnetic core column 52 without affecting the routing of the coil. In some embodiments, the inductor lead 6 can be either a wiring conductive bar 61 connected to the coil, or a signal line for transmitting signals.

[0059] Specifically, when the yoke column insulator 22 is injection-molded on the yoke column 21 , the first column 211 and the second column 212 are injection-molded respectively. The yoke column insulator 22 includes a first injection-molded portion on the first column 211 and a second injection-molded portion on the second column 212 .

[0060] In one embodiment, please refer to Fig.13 The first inductor coil 11 is connected in parallel with the second inductor coil 21, and the inductor includes an inductor copper bar 103. At least a portion of at least one inductor copper bar 103 is located in the column interval 213. In one embodiment, the number of input terminals 1031 of the inductor is one, and the number of output terminals 1032 is two.

[0061] In one embodiment, please refer to Fig. 9 , the first column 211 and the second column 212 can also be fitted together, and in this case, the column spacer 213 is no longer needed. In some other embodiments, the yoke column 21 is an integrated structure. In some other embodiments, the yoke column 21 can also be formed by stacking a plurality of magnetic core blocks 121 together.

[0062] Specifically, in one embodiment, please refer to Figure 4 , Figure 5 and Fig.11 In order to improve the stability of the first inductor insulator 31, the first inductor insulator 31 includes a surface portion 311 covering the outer surface of the end yoke 4 and an inner portion 312 located on the side of the end yoke 4 facing the first magnetic core column 12, the inner portion 312 is connected to the surface portion 311, and in the extension direction of the first magnetic core column 12, at least a portion of the inner portion 312 is located between the first insulator 13 and the end yoke 4. The inner portion 312 can better limit the separation of the first inductor insulator 31 from the end yoke 4.

[0063] In one embodiment, please refer to Figure 2 A mounting insert 7 is embedded in the inductor insulator 3 , and the mounting insert 7 has a mounting hole 71 , and the mounting hole 71 is used to mount the inductor to a target position.

[0064] In one embodiment, please refer to Figure 4 , Figure 5 and Fig.11 , there are two inner parts 312, namely the first inner part 3121 and the second inner part 3122. In the arrangement direction of the first magnetic core column 12 and the second magnetic core column 52, the first inner part 3121 is located between the first magnetic core column 12 and the second magnetic core column 52. In the arrangement direction of the yoke column 21 and the first magnetic core column 12, the second inner part 3122 is located on the side of the yoke column 21 facing the first magnetic core column 12, and both ends of the second inner part 3122 are connected to the surface part 311. One end of the first inner part 3121 is connected to the second inner part 3122, and the other end is connected to the surface part 311.

[0065] In one embodiment, based on the same concept, the structure of the second inductor insulator 32 is similar to that of the first inductor insulator 31 , and will not be described in detail.

[0066] In one embodiment, the inductor insulator 3 is molded after the first insulator 13 and the yoke column insulator 22 are injection molded. The first inductor 11 and the first magnetic core column 12 are fixed together by injection molding of the first inductor 13 to form a first assembly 1, and the first insulator 13 is filled into the gap between the first inductor 11 and the first magnetic core column 12. The yoke column insulator 22 is injection molded on the yoke column 21 to form a yoke column assembly 2, and the first positioning structure 221 is formed while the yoke column insulator 22 is molded, so that the first positioning structure 221 facilitates the assembly of the first inductor 11, the first insulator 13 and the yoke column 21. Similarly, the yoke column 21, the end yoke 4, the first magnetic core column 12 and the second magnetic core column 52 positioned together are fixed by the inductor insulator 3.

[0067] In one embodiment, the yoke column insulator 22 has a first positioning structure 221 for positioning the first inductor 11 (see Fig. 9 ). The yoke column insulator 22 and the first insulator 13 are separately injection molded, which is conducive to reducing the injection pressure of the injection molding process. Similarly, in one embodiment, please refer to Fig. 9 The yoke column insulator 22 has a second positioning structure 222 for positioning the second inductor 51 .

[0068] In one embodiment, please refer to Figure 8 and Fig. 9, the first positioning structure 221 includes a first positioning groove 2211, the yoke column insulator 22 clamps the first inductor 11 through the first positioning groove 2211, and the bottom surface of the first positioning groove 2211 is in contact with the surface of the first inductor 11. Similarly, in one embodiment, the second positioning structure 222 includes a second positioning groove 2221, and the yoke column insulator 22 clamps the second inductor 51 through the second positioning groove 2221. In some other embodiments, in addition to the positioning groove, the first positioning structure 221 may also include a positioning block, and in this case, a positioning groove or positioning hole adapted to the positioning block may be formed on the first insulator 13.

[0069] In one embodiment, please refer to Fig. 9 The yoke column insulator 22 is an injection molding cylinder, the yoke column 21 is flat, and the first positioning structure 221 and the second positioning structure 222 are located outside the cylinder wall of the injection molding cylinder.

[0070] Further, in one embodiment, please refer to Figure 4 , Figure 5 and Fig.10 The inductor includes a pre-positioning member 10, which connects the first insulator 13 and the second insulator 53 and is used to pre-position the first insulator 13 and the second insulator 53. Before the inductor insulator 3 fixes the first magnetic core column 12 and the second magnetic core column 52, the pre-positioning member 10 pre-positions the first magnetic core column 12 and the second magnetic core column 52.

[0071] For details, please refer to Figure 4 and Fig.10 The pre-positioning member 10 is a positioning plate, and a protrusion 101 is provided on the positioning plate. The first insulator 13 and the second insulator 53 are provided with a positioning hole 102 for inserting the protrusion 101. After the protrusion 101 is inserted into the positioning hole 102, the positioning plate pre-positions the first insulator 13 and the second insulator 53 together, so as to facilitate the assembly of the yoke column 21, the first magnetic core column 12 and the second magnetic core column 52. Furthermore, there are two positioning plates, and the two positioning plates are respectively located at the two ends of the extension direction of the first insulator 13. The positioning protrusion 101 is located on the opposite side of the two positioning plates. During installation, the protrusion 101 is inserted into the positioning hole 102 along the extension direction of the first magnetic core column 12.

[0072] Further, in one embodiment, please refer to Figure 1 , Figure 2 , Figure 5 and Figure 6The inductor lead 6 of the inductor includes a wiring conductive bar 61. In order to improve the stability of the wiring conductive bar 61, the wiring conductive bar 61 includes a first wiring conductive bar 611 connected to the first inductor coil 11, and the inductor insulator 3 includes a conductive bar injection molding portion 321 injected onto the first wiring conductive bar 611. In this way, the strength of the first wiring conductive bar 611 can be improved, and the first wiring conductive bar 611 is less likely to shake and is not easily bent and deformed. In particular, for some wiring conductive bars 61 with special structures, for example, due to the requirements of the installation position, the first wiring conductive bar 611 needs to extend a long distance. At this time, the first wiring conductive bar 611 is fixed after injection molding using the inductor insulator 3, so that the stability of the first wiring conductive bar 611 is better. In one embodiment, the first wiring conductive bar 611 is also connected to the second inductor coil 51.

[0073] In one embodiment, please refer to Figures 1 to 12 , an inductor forming method comprises the following steps:

[0074] The first inductor 11 of the inductor is sleeved on the periphery of the first magnetic core column 12, the first magnetic core column 12 and the first inductor 11 are fixed by injection molding the first insulator 13, and at least a portion of the first insulator 13 is filled into the gap between the first magnetic core column 12 and the first inductor 11, so as to prepare the first assembly 1.

[0075] The second inductor 51 of the inductor is sleeved on the outer periphery of the second magnetic core column 52, the second magnetic core column 52 and the second inductor 51 are fixed by injection molding the second insulator 53, and at least a portion of the second insulator 53 is filled into the gap between the second magnetic core column 52 and the second inductor 51, so as to prepare the second assembly 5.

[0076] A yoke column insulator 22 is injection molded on the yoke column 21 of the inductor, and a first positioning structure 221 and a second positioning structure 222 are formed on the yoke column insulator 22 to prepare a yoke column assembly 2 .

[0077] The first assembly 1 , the second assembly 5 and the yoke column assembly 2 are positioned and assembled, so that the first assembly 1 is positioned with the first positioning structure 221 , and the second assembly 5 is positioned with the second positioning structure 222 , and the first assembly 1 and the yoke column assembly 2 are fixed together by injection molding the inductor insulator 3 .

[0078] When the inductor insulator 3 is injection-molded, the first assembly 1, the second assembly 5 and the yoke column assembly 2 are fixed together.

[0079] By injecting the insulator in the inductor in batches, the first inductor coil 11 and the first magnetic core column 12 are pre-injected and fixed together, so that the injection pressure required for the first insulator 13 is less than the injection pressure of the entire inductor, and the first magnetic core column 12 is subjected to a smaller injection pressure and is less likely to be damaged, thereby improving the yield of the inductor. Similarly, the injection pressure on the yoke column 21 is also smaller, and the first positioning structure 221 formed on the yoke column insulator 22 facilitates the assembly of the first magnetic core column 12 and the yoke column 21, which can improve the molding efficiency of the inductor. When the first magnetic core column 12, the second magnetic core column 52 and the yoke column 21 are fixed by the inductor insulator 3, since the first insulator 13 fixes the first magnetic core column 12 and the first inductor coil 11, the first magnetic core column 12 and the first inductor coil 11 have a higher overall pressure resistance, can withstand a larger injection pressure, are not easily damaged by the injection pressure, and the molded inductor has a higher yield.

[0080] In one embodiment, the injection molding pressure of the inductor insulator 3 is greater than the injection molding pressure of the first insulator 13, and greater than the injection molding pressure of the second insulator 53, and greater than the injection molding pressure of the yoke column insulator 22. In some other embodiments, the injection molding pressures of different insulators can be set as needed, for example, the injection molding pressure of the inductor insulator 3 can also be less than or equal to the injection molding pressure of the first insulator 13. The injection molding pressure of the inductor insulator 3 can also be less than or equal to the injection molding pressure of the second insulator 53. The injection molding pressure of the inductor insulator 3 can also be less than or equal to the injection molding pressure of the yoke column insulator 22.

[0081] For details, please refer to Figures 1 to 11 , the detailed steps of the inductor forming method in one embodiment are as follows:

[0082] The first inductor 11 and the first magnetic core 12 are positioned and assembled in an injection mold, and then injection molded to form a first assembly 1. The structure of the first assembly 1 has been described in detail above and will not be repeated here. The second assembly 5 is formed in the same way.

[0083] The yoke column 21 is positioned and placed into an injection mold, and a yoke column insulator 22 is injection-molded on the yoke column 21 to form a yoke column assembly 2 .

[0084] After the wiring conductive bar 61 is installed, the first assembly 1, the second assembly 5, the yoke column assembly 2, the end yoke 4 and the insert are positioned and placed into the injection mold for injection molding. The injection-molded inductor insulator 3 fixes the above components together and makes the inductor insulator 3 cover part of the wiring conductive bar 61 to form the main body of the inductor, and then the other inductor leads 6 can be installed.

[0085] In one embodiment, the inductor is a high-power inductor, which can be applied to automobiles, such as in high-power voltage conversion circuits. Specifically, in one embodiment, the inductor is a boost inductor connected in parallel.

[0086] In one embodiment, the magnetically integrated inductor adopts an integrated injection molding process with high overall dimensional accuracy, and is suitable for a heat dissipation process in which a thermally conductive silicone gasket is installed at the bottom of the coil. Compared with traditional potted inductors, it has a smaller size, lighter weight, and better heat dissipation performance.

[0087] In one embodiment, based on the principle of heat dissipation of the bottom coil of the inductor, when the size of the inductor in the width direction (i.e., the first direction) is limited, the yoke column is designed to be connected to the end yoke at the top of the coil, thereby saving width space for the coil, increasing the heat dissipation area of ​​the coil, and improving the heat dissipation effect.

[0088] In one embodiment, the coil uses a flat metal wire, which is thinner and saves the amount of metal wire. As the metal wire is thinner, the length of the first magnetic core column and the second magnetic core column is also reduced, thereby saving the amount of magnetic core and further reducing the cost of raw materials. In one embodiment, the first inductor coil and the second inductor coil are wound in the same way, both are forward winding or both are reverse winding.

[0089] The above specific examples are used to illustrate the present invention, which is only used to help understand the present invention and is not intended to limit the present invention. For those skilled in the art, according to the concept of the present invention, some simple deductions, modifications or substitutions can be made.

Claims

1. An inductor, characterized in that: The invention comprises a first inductor, a second inductor, a first magnetic core column, a second magnetic core column, a yoke column and an end yoke; the first inductor is sleeved on the periphery of the first magnetic core column and a first insulator is filled between the two, the second inductor is sleeved on the periphery of the second magnetic core column and a second insulator is filled between the two, the end yoke is located at the end of the yoke column, and the magnetic path between the yoke column and the first magnetic core column and the magnetic path between the yoke column and the second magnetic core column are both conducted through the end yoke; The first magnetic core column and the second magnetic core column are arranged in a first direction, the first magnetic core column, the second magnetic core column and the yoke column all extend along the second direction, and the first direction is perpendicular to the second direction; the first direction and the second direction are both perpendicular to a third direction, and the yoke column is arranged on one side of the first magnetic core column in the third direction.

2. The inductor according to claim 1, characterized in that The end of the first magnetic core column, the end of the second magnetic core column and the end of the yoke column are all magnetically conductive with the end yoke; the end yoke includes a first magnetic core column conductive surface that is magnetically conductive with the first magnetic core column, a second magnetic core column conductive surface that is magnetically conductive with the second magnetic core column, and a yoke column conductive surface that is magnetically conductive with the yoke column, the first magnetic core column conductive surface is perpendicular to the yoke column conductive surface, and the first magnetic core column conductive surface and the second magnetic core column conductive surface are both on one side of the end yoke in the second direction.

3. The inductor according to claim 1 or 2, characterized in that: The inductor comprises a yoke column insulator, the yoke column insulator is covered on the yoke column, and the side surface of the first inductor coil facing the yoke column and the side surface of the second inductor coil facing the yoke column are both in contact with the yoke column insulator.

4. The inductor according to claim 3, characterized in that The side surface of the first inductor coil facing away from the yoke column and the side surface of the second inductor coil facing away from the yoke column are both exposed heat dissipation surfaces, and the heat dissipation surfaces are used to fit with a thermal pad for heat dissipation.

5. The inductor according to claim 4, characterized in that The inductor includes an inductor insulator, which fixes the yoke column, the end yoke, the first magnetic core column and the second magnetic core column. The inductor insulator includes an extrusion protrusion protruding toward the third direction, and the extrusion protrusion is arranged on the periphery of the heat dissipation surface to squeeze the thermal pad to make the thermal pad concave.

6. The inductor according to claim 1 or 2, characterized in that: The yoke column is in a flat plate shape.

7. The inductor according to claim 1 or 2, characterized in that: The yoke column includes a first column and a second column, the first column and the second column are arranged along a first direction, the first column and the second column are in contact with each other, or the first column and the second column are arranged at intervals along the first direction and form a column gap, the inductor includes an inductor lead, at least one of the inductor leads and / or the terminal of the first inductor coil and / or the terminal of the second inductor coil passes through the column gap.

8. The inductor according to claim 1 or 2, characterized in that: The inductor is a magnetically integrated staggered parallel inductor, and the first inductor coil is connected in parallel with the second inductor coil.

9. The inductor according to claim 1 or 2, characterized in that: The inductor includes a first inductor insulator and a second inductor insulator, the first inductor insulator and the second inductor insulator are arranged at intervals in the extension direction of the yoke column, at least one of the end yokes is a first yoke magnetically connected to one end of the yoke column, and at least one of the end yokes is a second yoke magnetically connected to the other end of the yoke column; the first inductor insulator fixes one end of the yoke column to the first yoke, and the second inductor insulator fixes the other end of the yoke column to the second yoke.

10. The inductor according to claim 9, characterized in that The first inductor insulator includes a surface portion covering the outer surface of the first magnetic yoke and an inner portion located on the side of the first magnetic yoke facing the first magnetic core column, wherein the inner portion is connected to the surface portion; in the extension direction of the first magnetic core column, at least a portion of the inner portion is located between the first insulator and the end magnetic yoke.

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