Integrally-formed inductor

Abstract

According to the integrated inductor, the insulation, voltage resistance and processing technology among the multiple windings of the integrated inductor are optimized, on one hand, the high-temperature-resistant insulation material is arranged between the first main winding and the first auxiliary winding, the pressing and annealing technological process is optimized, the dynamic inductance value of the inductor is reduced, and the voltage resistance of the inductor is improved; and the voltage withstanding requirement between the first main winding and the first auxiliary winding is met. And on the other hand, aiming at the multi-phase integrated inductor, the insulating material with high temperature resistance is arranged between the windings, and the insulation and voltage resistance between the windings are realized through the technological processes of two times of pressing and annealing, and meanwhile, the characteristics of small equivalent dynamic inductance, high frequency, low loss and high saturation are met.

Description

Technical Field

[0001] The present invention relates to the field of voltage regulation modules, and in particular to an integrally formed inductor. Background Art

[0002] In recent years, with the development of technologies in the fields of data centers, artificial intelligence, and supercomputers, more and more powerful ASICs have been applied, such as CPUs, GPUs, machine learning accelerators, network switches, and servers, which consume a lot of current, for example, the required current can reach thousands of amperes; and its current has the characteristics of rapid jump. Traditionally, a voltage regulator module (VRM, Voltage Regulator Modules, i.e., the power converter module involved in the present invention) composed of a buck circuit (Buck) is used to supply such a load. At the same time, in order to meet the amplitude and rapid jump of the load current, the number of phases of the buck circuit and the capacitance of its output decoupling capacitor are increased. These methods have improved the transient response capability of traditional VR to a certain extent; however, due to factors such as the large output impedance of VR, the large space occupied by the decoupling capacitor, and the long distance between the decoupling capacitor and the load, the traditional VR cannot meet the current performance requirements in terms of transient response. On the other hand, other technologies to improve traditional VR, such as increasing the switching frequency of VR and / or reducing the inductance value, can improve the transient response capability, but at the expense of reduced efficiency. In addition, the reverse coupling inductor technology has a relatively low leakage inductance, so it has a relatively fast transient response; at the same time, the reverse coupling inductor has a high steady-state equivalent inductance, which is conducive to improving efficiency; that is, the reverse coupling inductor technology can not only meet the requirements of transient performance, but also take into account the improvement of efficiency. Therefore, the reverse coupling technology is currently a commonly used technology for VR. However, because the reverse coupling inductor contains multiple windings, and the multiple windings need to be physically coupled to each other, it is difficult to manufacture; and the application is not flexible enough. The inductor of the trans-inductor voltage regulator technology (hereinafter referred to as TLVR inductor) can achieve coupling of multi-phase independent inductors that are not physically coupled through auxiliary windings; to solve the difficulties in manufacturing reverse coupling inductors; therefore, multi-phase Buck step-down VRM (Voltage Regulator Modules) using TLVR inductors have become a design hotspot for low-voltage and high-current power supply applications. Summary of the invention

[0003] The present invention is directed to the TLVR inductor. On the one hand, it proposes a series of insulation withstand voltage methods between windings, and matches the corresponding one-piece molded inductor processing technology and structure, while meeting the voltage regulation module's requirements for the equivalent dynamic inductance, high inter-winding withstand voltage and low power loss of the TLVR inductor.

[0004] On the one hand, the present invention provides an integrally formed inductor, comprising a magnetic core, a first main winding, a first auxiliary winding and an insulating material; the first main winding and the first auxiliary winding are arranged adjacent to each other; the insulating material is arranged between the first main winding and the first auxiliary winding, and the insulating material is an insulating, non-magnetic and high-temperature resistant material.

[0005] Preferably, the magnetic core is composed of magnetic powder particles, and the magnetic powder particles, the first main winding, the first auxiliary winding and the insulating material are formed into the integrally formed magnetic core and the integrally formed inductor through a one-time pressing and annealing process; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0006] Preferably, the magnetic core is composed of magnetic powder particles, the magnetic powder particles and the first main winding are pressed together to form a first inductor blank, and the magnetic powder particles and the first auxiliary winding are pressed together to form a second inductor blank; the first inductor blank and the second inductor blank both include a bonding surface.

[0007] Preferably, the first main winding comprises a first exposed surface, the first exposed surface is exposed to the bonding surface of the first inductor stock material, the first exposed surface is recessed in the bonding surface of the first inductor stock material to form a groove, and the groove is used for coating and accommodating insulating material.

[0008] Preferably, the bonding surface of the first inductor blank and the bonding surface of the second inductor blank are bonded and assembled, and the magnetic core and the one-piece molded inductor are formed through secondary pressing and annealing processes; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0009] Preferably, the first auxiliary winding comprises a second exposed surface, the second exposed surface is exposed to the bonding surface of the second inductor blank, and the insulating material is coated on the second exposed surface.

[0010] Preferably, the bonding surface of the first inductor blank and the bonding surface of the second inductor blank are bonded and assembled, and the magnetic core and the one-piece molded inductor are formed through secondary pressing and annealing processes; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0011] Preferably, it also includes a second main winding and a second auxiliary winding, and the second main winding and the second auxiliary winding are arranged adjacent to each other; the insulating material is also arranged between the second main winding and the second auxiliary winding; the first main winding, the insulating material, the first auxiliary winding, the second auxiliary winding, the insulating material and the second main winding are arranged in sequence.

[0012] Preferably, the magnetic core is composed of magnetic powder particles, and the magnetic powder particles and the first winding are pressed once to form a first inductor blank; the magnetic powder particles and the second winding are pressed once to form a second inductor blank; the magnetic powder particles, the first auxiliary winding and the second auxiliary winding are pressed once to form a third inductor blank; the first inductor blank, the second inductor blank and the third inductor blank all include a bonding surface.

[0013] Preferably, the first main winding includes a first exposed surface, the first exposed surface is exposed to the bonding surface of the first inductor stock material, the first exposed surface is recessed in the bonding surface of the first inductor stock material to form a groove, and the groove is used to coat and accommodate insulating material; the second main winding includes a second exposed surface, the second exposed surface is exposed to the bonding surface of the second inductor stock material, the second exposed surface is recessed in the bonding surface of the second inductor stock material to form a groove, and the groove is used to coat and accommodate insulating material.

[0014] Preferably, the bonding surface of the first inductor blank coated with insulating material and the bonding surface of the third inductor blank are bonded and assembled, and the bonding surface of the second inductor blank coated with insulating material and the bonding surface of the third inductor blank are bonded and assembled; the magnetic core and the one-piece molded inductor are formed by secondary pressing and annealing process; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0015] Preferably, the magnetic core is composed of magnetic powder particles, the first winding, the second winding and the magnetic powder particles are pressed together to form a first inductor blank, and the first auxiliary winding, the second auxiliary winding and the magnetic powder particles are pressed together to form a second inductor blank; the first inductor blank and the second inductor blank both include a first bonding surface and a second bonding surface; the first inductor blank is concave in shape, and the second inductor blank is I-shaped.

[0016] Preferably, the first winding is exposed on the first fitting surface of the first inductor blank and is recessed in the first fitting surface to form a first groove; the second winding is exposed on the second combination surface of the second inductor blank and is recessed in the second combination surface to form a second groove; the first groove and the second groove are used for coating and accommodating insulating materials.

[0017] Preferably, the first bonding surface of the first inductor blank coated with insulating material is bonded to the first bonding surface of the second inductor blank, and the second bonding surface of the first inductor blank coated with insulating material is bonded and assembled to the second bonding surface of the second inductor blank; the magnetic core and the one-piece molded inductor are formed by secondary pressing and annealing process; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0018] On the other hand, the present invention provides an integrally formed inductor, comprising a magnetic core, a first main winding, a first auxiliary winding and an insulating material; the first main winding and the first auxiliary winding are arranged adjacent to each other; the insulating material covers the first auxiliary winding, and the insulating material is an insulating, non-magnetic and high-temperature resistant material.

[0019] Preferably, the first auxiliary winding, the first main winding and the magnetic powder material coated with the insulating material are subjected to a pressing and annealing process to form the magnetic core and the one-piece molded inductor; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0020] Preferably, it also includes a second winding and a second auxiliary winding, the second main winding and the second auxiliary winding are arranged adjacent to each other; the insulating material covers the second auxiliary winding; the first main winding, the first auxiliary winding covered with insulating material, the second auxiliary winding covered with insulating material and the second main winding are arranged in sequence.

[0021] Preferably, the first auxiliary winding coated with insulating material, the first main winding, the second auxiliary winding coated with insulating material, the second winding and the magnetic powder material are subjected to pressing and annealing processes to form the magnetic core and the one-piece molded inductor; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

[0022] Preferably, the first winding includes a first pin and a second pin, the first auxiliary winding includes a first pin and a second pin; the magnetic core includes relative bottom and top surfaces; the second pin of the first winding and the first pin and the second pin of the first auxiliary winding extend toward the bottom surface of the magnetic core.

[0023] Preferably, the first main winding and the second main winding both include a first pin and a second pin, and the first auxiliary winding and the second auxiliary winding both include a first pin and a second pin; the magnetic core includes relative top and bottom surfaces; the second pin of the first winding and the second pin of the second winding and the first pin and the second pin of the first auxiliary winding and the second auxiliary winding all extend toward the bottom surface of the magnetic core, and the first pin of the first main winding and the second main winding both extend toward the top surface of the magnetic core.

[0024] Preferably, the first pin of the first winding and the first pin of the second winding are arranged adjacent to the same side of the magnetic core, and the second pin of the first winding and the second pin of the second winding are arranged adjacent to the other side of the magnetic core.

[0025] Preferably, the first pin of the first winding and the second pin of the second winding are arranged adjacent to the same side of the magnetic core, and the second pin of the first winding and the first pin of the second winding are arranged adjacent to the other side of the magnetic core.

[0026] The present invention has the following beneficial effects:

[0027] (1) The present invention optimizes the insulation withstand voltage and processing technology between multiple windings of an integrally formed inductor. By setting a high-temperature-resistant insulating material between the first main winding and the first auxiliary winding, the pressing and annealing process flow is optimized, the dynamic inductance of the inductor is reduced, and the withstand voltage requirement between the first main winding and the first auxiliary winding is met.

[0028] (2) The present invention is directed to a multi-phase integrated inductor. By placing a high-temperature-resistant insulating material between windings and performing two pressing and annealing process flows, the insulation withstand voltage between the windings is achieved while satisfying the characteristics of small equivalent dynamic inductance, high frequency low loss and high saturation. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0030] Figure 1a It is the schematic diagram of the principle of N-phase buck circuit using TLVR inductor;

[0031] Figure 1b It is a schematic diagram of the principle of an N-phase buck circuit using two-phase integrated TLVR inductors;

[0032] Figure 2a to Figure 2c is a schematic structural diagram of a TLVR inductor 100a;

[0033] Figure 3a to Figure 3c is a schematic diagram of the structure of the TLVR inductor 100b;

[0034] Figures 4a to 4d is a schematic diagram of the structure of the TLVR inductor 100c;

[0035] Figure 4e to Figure 4f It is a schematic diagram of the structure of the TLVR inductor 100d;

[0036] Figure 5a to Figure 5b It is a schematic diagram of the structure of a two-phase integrated TLVR inductor 200a;

[0037] Figure 6a to Figure 6b It is a schematic diagram of the structure of a two-phase integrated TLVR inductor 200b;

[0038] Figure 7a to Figure 7b It is a schematic diagram of the structure of a two-phase integrated TLVR inductor 200c;

[0039] Figure 8a to Figure 8b It is a schematic diagram of the structure of a two-phase integrated TLVR inductor 200d;

[0040] Figures 9a to 9c It is a schematic diagram of the structure of the reverse-coupled TLVR inductor 200e;

[0041] in:

[0042] 100 / 100a / 100b / 100c / 100d TLVR inductor; 110 / 113 / 114 / 115 / 116 magnetic core; 111 first magnetic core; 111a / 114a / 115a first inductor stock; 111b first inductor; 112 second magnetic core; 112a / 114b / 115b second inductor stock; 112b second inductor; 113a / 116a top surface; 113b / 116b bottom surface; 113c / 113d / 116c / 116d side surface; 114c third inductor stock; 121 first main winding; 121a / 122a first end; 12 1b / 122b second end; 122 second main winding; 131 first auxiliary winding; 132 second auxiliary winding; 141 / 142 / 151 / 152 / 171 insulating material; 141a width of insulating material; 161a / 161b / 162a / 162b combination surface; 170 groove; 200 / 200a / 200b / 200c / 200d / 200e two-phase integrated TLVR inductor; L1 / L2 / … / Ln independent inductor; L10 / L20 / … / Ln0 auxiliary winding; Le external compensation inductor. DETAILED DESCRIPTION

[0043] One of the cores of the present invention is to optimize the insulation withstand voltage and processing technology between multiple windings of the one-piece molded inductor. On the one hand, by setting the high temperature resistant insulating material between the first main winding and the first auxiliary winding, the pressing and annealing process flow is optimized, the dynamic inductance of the inductor is reduced, and the withstand voltage requirement between the first main winding and the first auxiliary winding is met. On the other hand, for multi-phase integrated inductors, by setting the high temperature resistant insulating material between the windings, through two pressing and annealing process flows, the insulation withstand voltage between the windings is achieved, while meeting the characteristics of small equivalent dynamic inductance, high frequency low loss and high saturation.

[0044] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0045] Figure 1a The figure shows the principle diagram of the inductor (hereinafter referred to as TLVR inductor) and N-phase buck circuit (Buck) using the Trans-inductor voltage regulator technology. The main windings L1, L2...Ln are N independent inductors that are not coupled to each other, and L10, L20...Ln0 are N auxiliary windings. The auxiliary windings L10, L20...Ln0 are coupled with the main windings L1, L2...Ln respectively; each main winding is coupled with a corresponding auxiliary winding to form a TLVR inductor (for example, the main winding L1 and the auxiliary winding L10 form a TLVR inductor). Figure 1a Here, the main winding can also be called the primary winding, and the auxiliary winding can also be called the secondary winding. Figure 1a In the embodiment shown, taking four auxiliary windings L10, L20, L30 and L40 as an example, the four auxiliary windings are connected in series in order of first position, so that the four independent inductors L1, L2, L3 and L4 without coupling relationship are equivalent to four-phase coupled inductors with coupling relationship; in this embodiment, an external compensation inductor Le is also included, which is connected in series in the series loop of the four auxiliary windings. When the phase difference between the four-phase control signals of the four-phase buck circuit is 360 / 4 degrees, a four-phase TLVR inductor is formed. Compared with the case where the four-phase inductors L1, L2, L3 and L4 have no auxiliary windings, the equivalent steady-state inductance of each phase of the four-phase TLVR inductor is slightly reduced, but the equivalent dynamic inductance of each phase is greatly reduced. The number of phases in the above embodiments can be expanded to N phases, and in the same connection mode, when the phase difference between the N-phase control signals of the N-phase buck circuit is 360 / N degrees, an N-phase TLVR inductor is formed. Compared with the case where the N-phase inductors L1, L2, L3, ... Ln have no auxiliary winding, the equivalent steady-state inductance per phase of the N-phase TLVR inductor is slightly reduced, but the equivalent dynamic inductance per phase is greatly reduced. The coupling between the main winding and the auxiliary winding disclosed in the present invention can greatly reduce the equivalent dynamic inductance of each phase inductor in the voltage regulator module composed of the step-down circuit, thereby improving the dynamic performance of the voltage regulator module.

[0046] In the voltage regulation module using the anti-coupled inductor, the N-phase inductors are wound on the same magnetic core and realized through the physical coupling of magnetic flux. When a large load current flows through the main winding, the DC magnetic flux in the anti-coupled inductor cancels each other, so it is not easy to saturate. Figure 1b The schematic diagram of another N-phase buck circuit using TLVR inductors is shown, wherein a two-phase integrated TLVR inductor 200 is integrated in one inductor, which can not only improve the integration of the voltage regulation module and reduce the volume of the voltage regulation module, but also, the two main windings in each two-phase integrated TLVR inductor 200 can be anti-coupled, that is, multi-phase TLVR technology is realized on the basis of two anti-coupled inductors. Therefore, not only can the equivalent dynamic inductance of the voltage regulation module be further reduced, but also the DC magnetic flux of the anti-coupled two-phase main windings cancel each other out, under the same saturation conditions, the volume of the magnetic core can be further reduced, and the power density of the voltage regulation module can be improved.

[0047] like Figure 1a The N-phase main winding shown is an independent inductor (i.e., there is no physical coupling relationship). When a large load current flows through the main winding, the TLVR inductor is easily saturated. Traditional magnetic cores are generally made of ferrite materials, but due to the low saturation density of ferrite materials, they do not have advantages when used to make TLVR inductor cores. Metal magnetic powder core materials have good saturation characteristics and can be used to make metal magnetic powder core inductors through one-piece pressing and molding; there are two corresponding production methods, the first is direct hot pressing and the second is cold pressing. Specifically, in the first type of hot pressing method, insulation between metal magnetic powder particles is achieved by coating glue, but the relative magnetic permeability after hot pressing is relatively low, usually below 50. In the second type of cold pressing method, the metal magnetic powder core inductor that is pressed and formed into one piece is first ceramicized on the surface of the metal magnetic powder particles by high-temperature annealing, and the ceramic layer on the surface of the metal magnetic powder particles is used to achieve insulation between the metal magnetic powder particles, thereby reducing the core loss after pressing and forming. In addition, the high-frequency characteristics of the pressed core are good, the relative magnetic permeability is high (usually higher than 50), and the cost is low. For TLVR inductors, the use of magnetic materials with high relative magnetic permeability can increase the coupling coefficient between the main winding and the auxiliary winding, which is beneficial to reducing the equivalent dynamic inductance of the TLVR inductor. Therefore, the second type of cold pressing method using metal magnetic powder particles can meet the needs of TLVR inductors. On the other hand, in the present invention Figure 1aIn the circuit diagram shown, the TLVR inductor is usually a load with a large current flowing through the multi-phase main winding at the same time. Each auxiliary winding induces a voltage from the corresponding main winding. The multi-phase auxiliary windings are connected in series in a sequential manner, so that multiple induced voltages are accumulated and superimposed; in extreme cases, the highest potential difference between the N-phase auxiliary windings and the main winding after being connected in series may be close to N times the input voltage. Therefore, the main winding and the auxiliary winding of the TLVR inductor need to meet high insulation withstand voltage requirements. In addition, because the annealing temperature of the metal magnetic powder particles in the second type of cold pressing molding method is usually above 600 degrees Celsius, the excessively high annealing temperature requires special consideration of the high temperature resistance of the insulating material between the main winding and the auxiliary winding. In the annealing process of the one-piece molded TLVR inductor of the present invention, the insulation withstand voltage process between the main winding and the auxiliary winding and the structural design of the TLVR inductor propose innovative technical solutions.

[0048] The insulation method between the main winding and the auxiliary winding disclosed in the present invention is also applicable to the insulation between the main windings and the insulation between turns in a winding. The present invention is only described by taking the TLVR inductor structure as an example, but is not limited to this.

[0049] Embodiment 1

[0050] Figure 2a yes Figure 1a A schematic diagram of a structure of an embodiment of a TLVR inductor 100 is shown in FIG. Figure 2b yes Figure 2a Schematic diagram of the structural decomposition of Figure 2c yes Figure 2a See also Figure 2a to Figure 2c, the TLVR inductor 100a includes a magnetic core 110, a first main winding 121, a first auxiliary winding 131 and an insulating material 141. The first main winding 121 and the first auxiliary winding 131 have the same geometric shape and are arranged in parallel and adjacent to each other inside the magnetic core; the shape and arrangement of the first main winding 121 and the first auxiliary winding 131 can improve the coupling coefficient between the main winding and the auxiliary winding, reduce the equivalent dynamic inductance of the TLVR inductor 100a, and improve the dynamic performance of the multi-phase buck circuit using the TLVR inductor 100a. The insulating material 141 is arranged between the first main winding 121 and the first auxiliary winding 131. The insulating material 141 is used to prevent the first main winding 121 and the first auxiliary winding 131 from deforming during the one-time molding process of the TLVR inductor 100a, thereby preventing the short-circuit failure caused by the deformation. Under the condition of meeting the insulation withstand voltage requirements, the smaller the width 141a of the insulating material 141, the higher the coupling coefficient between the first main winding 121 and the first auxiliary winding 131, and the smaller the equivalent dynamic inductance of the TLVR inductor 100a; the insulating material 141 of this embodiment needs to have good insulation performance, be able to withstand high temperatures (for example, a temperature resistance higher than 600 degrees Celsius or higher than 800 degrees Celsius), and be non-magnetic (that is, the relative magnetic permeability is less than 10 or less than 5). The insulating material can be a ceramic material, but is not limited to this.

[0051] In some other embodiments, the TLVR inductor 100a may also include a magnetic core 110, a first main winding 121, a first auxiliary winding 131 and an insulating material 142, and the layout structure is similar to Figure 2a to Figure 2c The insulating material 142 is the same as the first main winding 121, except that the insulating material 142 does not have the property of high temperature resistance. Under high temperature conditions, the insulating material 142 can be completely oxidized or vaporized. In the one-time molding process of the TLVR inductor 100a of this embodiment, the insulating material 142 is only used to prevent the deformation of the first main winding 121 and the first auxiliary winding 131, which may cause short-circuit failure, and at the same time prevent the magnetic material from flowing between the first main winding 121 and the first auxiliary winding 131, and is conducive to fixing the position of the first main winding 121 and the first auxiliary winding 131. However, in subsequent processes such as high-temperature annealing, the insulating material 142 can be completely oxidized or vaporized at high temperatures. Setting the position of the insulating material 142 to be filled with air can also obtain Figure 2a to Figure 2c Technical features and benefits of the illustrated embodiments.

[0052] In this embodiment, the cross-sectional area of ​​the first main winding 121 needs to be larger than the cross-sectional area of ​​the first auxiliary winding 131. Because the load current flows through the first main winding 121, the large cross-sectional area of ​​the first main winding 121 can make the DC impedance of the first main winding 121 small, thereby reducing the DC loss of the main winding; in addition, the first auxiliary winding 131 only senses the changing AC current in the first main winding 121, so there is no DC loss on the first auxiliary winding 131, so the cross-sectional area of ​​the first auxiliary winding 131 can adopt a smaller cross-sectional area, thereby improving the conversion efficiency of the voltage regulation module.

[0053] Embodiment 2

[0054] Figure 3a yes Figure 1a A schematic diagram of the structure of another embodiment of the TLVR inductor 100, Figure 3b for Figure 3a Schematic diagram of the structural decomposition of Figure 3c for Figure 3a A cross-sectional view of the structure at position AA is shown. Figure 3a to Figure 3c As shown, the TLVR inductor 100b in this embodiment has the same technical effect as the TLVR inductor 100a shown in the first embodiment; the difference between this embodiment and the first embodiment is that, in this embodiment, no insulating material 141 is provided between the first main winding 121 and the first auxiliary winding 131, but a layer of insulating material 151 is coated on the surface of the first auxiliary winding 131, and the insulating material 151 has the characteristics of good insulation and high temperature resistance, such as low melting point ceramic material. The melting point of the insulating material 151 is higher than the annealing temperature of the metal magnetic powder particles (for example, higher than 600 degrees Celsius, or even higher than 800 degrees Celsius); the powder of the insulating material 151 is mixed with glue and coated on the surface of the first auxiliary winding 131 to completely cover the first auxiliary winding 131; after the glue is solidified, the surface of the first auxiliary winding 131 is covered with a layer of the insulating material 151 whose melting point is higher than the annealing temperature of the metal magnetic powder particles; the first auxiliary winding 131 covered with the insulating material 151, the first main winding 121 and the metal magnetic powder particles are pressed together to form the magnetic core 110 and the TLVR inductor 100b; and then the subsequent annealing process is performed. At this time, the first main winding 121 and the first auxiliary winding 131 have good insulation performance, and the distance between the first main winding 121 and the first auxiliary winding 131 is determined by the particle diameter of the insulating material 151.

[0055] In this embodiment, the thickness of the insulating material 151 coated on the surface of the first auxiliary winding 131 is small, so that the distance between the first main winding 121 and the first auxiliary winding 131 is short, which makes the coupling coefficient between the first main winding 121 and the first auxiliary winding 131 high, and the equivalent dynamic inductance of the TLVR inductor 100b is small, so the dynamic performance of the buck circuit based on the TLVR inductor 100b is good; at the same time, the above insulation method also strengthens the insulation performance between the first auxiliary winding 131 and the magnetic core 110, reduces the risk of short circuit between the first main winding 121 and the first auxiliary winding 131 through the magnetic core 110, and greatly improves the insulation withstand voltage performance between the main winding and the auxiliary winding of the TLVR inductor 100b. In addition, the distance between the first main winding 121 and the first auxiliary winding 131 is small, and the utilization rate of the magnetic core is improved. Compared with the first embodiment, under the same core cross-sectional area condition, the cross-sectional area of ​​the first main winding 121 can be larger, and the DC impedance of the first main winding 121 can be further reduced, which helps to further reduce the loss and improve the conversion efficiency of the voltage regulation module.

[0056] Furthermore, the insulating material 151 can be coated only on the surface of the first main winding 121, or the insulating material 151 can be coated on the surfaces of the first main winding 121 and the first auxiliary winding 131 at the same time, so as to further enhance the insulation performance between the first main winding 121 and the first auxiliary winding 131.

[0057] Embodiment 3

[0058] Figure 4a yes Figure 1a A schematic diagram of the structure of another embodiment of the TLVR inductor 100, Figure 4b and Figure 4c for Figure 4a Schematic diagram of the structural decomposition of Figure 4d is a side view. Figures 4a to 4dAs shown, the TLVR inductor 100c shown in this embodiment includes a first main winding 121, a first auxiliary winding 131, a first magnetic core 111 and a second magnetic core 112. The TLVR inductor 100c shown in this embodiment has the same technical effect as the TLVR inductor 100a in the first embodiment. The difference between this embodiment and the first embodiment is that the first main winding 121 and the metal magnetic powder particles are pressed and integrated to form a first inductor blank 111a, and the first auxiliary winding 131 and the metal magnetic powder particles are pressed and integrated to form a second inductor blank 112a; the first inductor blank 111a and the second inductor blank 112a are respectively subjected to an annealing process to form a first inductor 111b and a second inductor 112b, and a layer of insulating material 151 is coated on the winding parts on the combination surface 161a of the first inductor 111b and the combination surface 161b of the second inductor 112b, and then the first inductor 111b and the second inductor 112b are bonded and assembled together. Here, if no insulating material is provided on the cross section of the magnetic core on the combination surfaces 161a and 161b, the characteristic of small magnetic resistance of the combination portion between the magnetic cores can be obtained, which helps to improve the inductance of the TLVR inductor 100c. Therefore, in another embodiment, the exposed surface of the first main winding 121 on the side of the combination surface 161a is recessed in the combination surface 161a to form a groove (not shown). Similarly, the exposed surface of the first auxiliary winding 131 on the side of the combination surface 161b is recessed in the combination surface 161b to form a groove (not shown). The groove can be used to provide insulating material, so that no insulating material can be provided on the cross section of the magnetic core on the combination surfaces 161a and 161b.

[0059] After the annealing process in the integrated molding process of the TLVR inductor 100c disclosed in this embodiment, the first inductor 111b and the second inductor 112b are assembled. There may be an assembly gap between the assembly surfaces 161a and 161b of the assembled magnetic core. Figure 4b , the existence of the assembly gap will increase the magnetic resistance of the magnetic circuit, resulting in a decrease in the inductance of the TLVR inductor 100c, and a deterioration in the coupling performance between the first main winding 121 and the first auxiliary winding 131. Therefore, before the annealing process, the exposed surface of the first main winding 121 in the first inductor blank 111a and the exposed surface of the first auxiliary winding 131 in the second inductor blank 112a can be coated with an insulating material 171. The insulating material 171 can be a ceramic material or a raw ceramic tape of a low-temperature co-fired ceramic (LTCC). Then, after the first inductor blank 111a and the second inductor blank 112a are assembled together, a second pressing is performed. After the second pressing, the TLVR inductor is subjected to annealing and other process treatments as a whole to form the TLVR inductor 100c. The pressure of the second pressing is less than the pressure of the first pressing. Therefore, the compression ratio of the inductor blank after the first pressing in the second pressing is small, and the deformation amount generated is also small. At this time, if Figure 4dAs shown, after the first inductor blank 111a and the second inductor blank 112a are assembled and pressed twice, the assembly gap between the combination surfaces 161a and 161b also disappears due to the secondary pressing, and the insulating material 171 plays an insulating function between the first main winding 121 and the first auxiliary winding 131. Furthermore, if the insulating material 171 is LTCC, the low temperature co-firing temperature of LTCC is in the same range as the annealing temperature of the metal magnetic powder particles, so using LTCC as the insulating material is conducive to simplifying the production process of the TLVR inductor.

[0060] In this embodiment, there is an assembly gap between the assembled magnetic core assembly surfaces 161a and 161b. Alternatively, Figure 4e and Figure 4f Solution shown. Figure 4e is a side view schematic diagram of the TLVR inductor 100d, Figure 4f for Figure 4e Schematic diagram of the structural decomposition of. Figure 4e and Figure 4f , the TLVR inductor 100d includes a first magnetic core 111, a second magnetic core 112, a first main winding 121, a first auxiliary winding 131 and an insulating material 171. The first main winding 121 and the metal magnetic powder particles are pressed together to form a first inductor blank 111a, and the first auxiliary winding 131 and the metal magnetic powder particles are pressed together to form a second inductor blank 112a; the combination surface 161a of the first inductor blank 111a and the exposed surface of the first main winding 121 on the combination surface 161a side are not on the same horizontal plane, and the exposed surface of the first main winding 121 on the combination surface 161a side is concave in the combination surface 161a, and a groove 170 is formed. Figure 4f In the embodiment, the projection of the groove 170 on the combined surface 161a is larger than the projection of the first main winding 121 on the combined surface 161a (i.e., the cross-sectional area of ​​the groove 170 is larger than the cross-sectional area of ​​the first main winding 121). The groove 170 is used to accommodate the insulating material 171, and can prevent the insulating material 171 coated on the first main winding 112 from being squeezed out after the first inductor blank 111a and the second inductor blank 112a are assembled and pressed for the second time, and can ensure that the insulating material 171 can completely cover the exposed surface of the first main winding 121, thereby achieving insulation between the first main winding 121 and the first auxiliary winding 131. Similarly, the first auxiliary winding 131 can also adopt the above-mentioned groove method and the method of coating the insulating material 171, and also have the same technical features and benefits, which will not be repeated here.

[0061] Embodiment 4

[0062] Figure 5a is an embodiment of a two-phase integrated TLVR inductor 200, Figure 5b for Figure 5a Schematic diagram of the structural decomposition. Figure 5a to Figure 5b The two-phase integrated TLVR inductor 200a shown includes a magnetic core 113, a first main winding 121, a second main winding 122, a first auxiliary winding 131, a second auxiliary winding 132 and an insulating material 141. The first main winding 121 and the first auxiliary winding 131 are coupled to each other, and the second main winding 122 and the second auxiliary winding 132 are coupled to each other. The fourth embodiment is similar to the first embodiment in that an insulating material 141 is provided between the main winding and the corresponding auxiliary winding, and the insulating material 141 has the characteristics of good insulation, non-magnetic conductivity and high temperature resistance. The insulation technology and the pressing process of the TLVR inductor disclosed in the present embodiment are the same as those disclosed in the first embodiment, and will not be repeated here.

[0063] The difference between the fourth embodiment and the first embodiment is that the present embodiment includes two main windings (a first main winding 121 and a second main winding 122) and two auxiliary windings (a first auxiliary winding 131 and a second auxiliary winding 132), and the two main windings and the two auxiliary windings are arranged in the same magnetic core 113 and share part of the magnetic core, thereby improving the power density of the two-phase integrated TLVR inductor 200. For details, as shown in FIG. Figure 5b As shown, the first pin 121a of the first main winding 121 and the first pin 122a of the second main winding 122 are both adjacent to the same side 113d of the magnetic core 113 and extend toward the top surface 113a of the magnetic core 113, and the second pin 121b of the first main winding 121 and the second pin 122b of the second main winding 122 are both adjacent to the same side 113c of the magnetic core 113 and extend toward the bottom surface 113b of the magnetic core 113. Both pins of the first auxiliary winding 131 and the second auxiliary winding 132 extend toward the bottom surface 113b of the magnetic core 113; the first auxiliary winding 131 and the second auxiliary winding 132 are disposed between the first main winding 121 and the second main winding 122. Of course, in some other embodiments, the first main winding 121 and the second main winding 122 may also be arranged between the first auxiliary winding 131 and the second auxiliary winding 132; no matter which arrangement is used, as long as the first main winding 121 and the first auxiliary winding 131 are arranged adjacent to each other, the second main winding 122 and the second auxiliary winding 132 may also be arranged adjacent to each other, thereby improving the coupling performance and coupling coefficient between the main winding and the auxiliary winding, reducing the equivalent dynamic inductance of the two-phase integrated TLVR inductor, and improving the dynamic performance of the voltage regulation module using the two-phase integrated TLVR inductor.

[0064] Embodiment 5

[0065] Figure 6a Another embodiment of a two-phase integrated TLVR inductor 200 is shown in FIG. Figure 6b for Figure 6aThe cross-sectional schematic diagram of the AA position is shown. The two-phase integrated TLVR inductor 200b of this embodiment includes a magnetic core 113, a first main winding 121, a second main winding 122, a first auxiliary winding 131, a second auxiliary winding 132 and an insulating material 151. The structure and layout of the two main windings and the two auxiliary windings are the same as those shown in the fourth embodiment, and are not repeated here. The insulation treatment method of this embodiment is the same as that of the second embodiment, that is, the insulating material 151 is coated on the surface of the first auxiliary winding 131 and the second auxiliary winding 132, and then the first main winding 121, the second main winding 122, the first auxiliary winding 131, the second auxiliary winding 132 and the metal magnetic powder particles are pressed together, and then annealing treatment and other processes are performed to form the magnetic core 113 and the two-phase integrated TLVR inductor 200b.

[0066] In this embodiment, if Figure 6b As shown, the insulating material 151 can also be replaced by the insulating material 152, and the insulating material 152 is an insulating material with a certain bonding strength, that is, the insulating material 152 includes physical particles with a certain physical diameter and a certain hardness, such as ceramic powder or glass beads, etc., which are mixed with glue and coated on the surface of the auxiliary winding. The first main winding 121 and the first auxiliary winding 131 are bonded by the insulating material 152 to form a first winding combination, and the second main winding 122 and the second auxiliary winding 132 are bonded by the insulating material 152 to form a second winding combination. After the glue is cured; the first winding combination, the second winding combination and the metal magnetic powder particles are pressed together, and after annealing and other process treatments, the magnetic core 113 and the two-phase integrated TLVR inductor 200b are formed. This method of first combining the windings and then pressing them with the metal magnetic powder particles can prevent the position between the main winding and the auxiliary winding from being displaced during the pressing process, thereby preventing the coupling coefficient between the main winding and the corresponding auxiliary winding from being reduced; at the same time, the pressing process is simplified, saving manufacturing costs. The method of combining first and then pressing disclosed in this embodiment is also applicable to Figure 5a and Figure 5b In the fourth embodiment shown, the insulating material 141 in the fourth embodiment is replaced by an insulating material 152, and the main winding and the corresponding auxiliary winding are bonded to form a first winding combination and a second winding combination by utilizing the adhesiveness of the insulating material 152. The first winding combination, the second winding combination and the metal magnetic powder particles are then pressed together, and after annealing and other process treatments, a magnetic core 113 and a two-phase integrated TLVR inductor 200b are formed. In addition to having the technical features and benefits of the fourth embodiment, the two-phase integrated TLVR inductor 200b using the insulating material 152 prevents the position between the main winding and the auxiliary winding from being displaced during the pressing process, thereby preventing the coupling coefficient between the main winding and the corresponding auxiliary winding from being reduced; at the same time, the pressing process is simplified, saving manufacturing costs.

[0067] Embodiment 6

[0068] Figure 7a Another embodiment of a two-phase integrated TLVR inductor 200 is shown in FIG. Figure 7b for Figure 7a The structural decomposition diagram of the two-phase integrated TLVR inductor 200c (as shown in FIG. Figure 7a The structure of the two-phase integrated TLVR inductor 200c in this embodiment includes a magnetic core 114, a first main winding 121, a second main winding 122, a first auxiliary winding 131, a fourth auxiliary winding 132 and an insulating material 171. The first main winding 121 and the metal magnetic powder particles are pressed together to form a first inductor stock 114a, the second main winding and the metal magnetic powder particles are pressed together to form a second inductor stock 114b, and the first auxiliary winding 131, the second auxiliary winding 132 and the metal magnetic powder particles are pressed together to form a third inductor stock 114c; the structures of the first inductor stock 114a and the second inductor stock 114b are similar to those in the embodiment. Figure 4f The first inductor stock 111a in the illustrated embodiment is the same; in the first inductor stock 114a, the exposed surface of the first winding 121 on the side of the combination surface 161a is recessed in the combination surface 161a to form a groove for accommodating the insulating material 171; in the second inductor stock 114b, the exposed surface of the second winding 122 on the side of the combination surface 162a is recessed in the combination surface 162a to form a groove for accommodating the insulating material 171; the insulating material 171 here can also be replaced by the insulating material 152. The first inductor stock 114a coated with the insulating material 171, the second inductor stock 114b coated with the insulating material 171, and the third inductor stock 114c are assembled together, and secondary pressing is performed, and then annealing and other process treatments are performed after the secondary pressing. During the secondary pressing, the deformation of the first inductor blank 114a, the second inductor blank 114b and the third inductor blank 114c is small, and the insulation requirements between the main winding and the corresponding auxiliary winding are met, simplifying the one-piece molding process.

[0069] Embodiment 7

[0070] Figure 8a Another embodiment of a two-phase integrated TLVR inductor 200 is shown in FIG. Figure 8b for Figure 8a The two-phase integrated TLVR inductor 200d (such as Figure 8aThe structure of the two-phase integrated TLVR inductor 200d in this embodiment is similar to the overall structure of the two-phase integrated TLVR inductor 200b in Example 5 and has the same technical effect; the inductor insulation process and inductor forming method shown in this embodiment are different from those in Example 5. The two-phase integrated TLVR inductor 200d in this embodiment includes a magnetic core 115, a first main winding 121, a second main winding 122, a first auxiliary winding 131, a fourth auxiliary winding 132 and an insulating material 171. The first main winding 121, the second main winding 122 and the metal magnetic powder particles are pressed together to form a first inductor blank 115a; the first auxiliary winding 131, the second auxiliary winding 132 and the metal magnetic powder particles are pressed together to form a second inductor blank 115b. In the first inductor blank 115a, the exposed surface of the first winding 121 on the side of the combination surface 161a is concave in the combination surface 161a, forming a groove for accommodating the insulating material 171; the exposed surface of the second winding 122 on the side of the combination surface 162a is concave in the combination surface 162a, forming a groove for accommodating the insulating material 171. The overall shape of the first inductor blank 115a is a "concave" shape, and the second inductor blank is an "l" shape. The combination of the two is a rectangular parallelepiped or a cube. After the first inductor blank 115a and the second inductor blank 115b coated with the insulating material 171 are assembled and subjected to secondary pressing, annealing and other process treatments are performed. In the secondary pressing, the deformation of the first inductor blank 115a and the second inductor blank 115b is small, and the insulation requirements between the main winding and the corresponding auxiliary winding are met, simplifying the one-piece molding process.

[0071] Embodiment 8

[0072] Figure 9a Another embodiment of a two-phase integrated TLVR inductor 200 is shown in FIG. Figure 9b for Figure 9a Schematic diagram of the structural decomposition of Fig.9c for Figure 9a Sectional view at position AA. Figures 9a to 9c The two-phase integrated TLVR inductor 200e shown in this embodiment includes a magnetic core 116, a first main winding 121, a second main winding 122, a first auxiliary winding 131, a second auxiliary winding 132 and an insulating material 171. Figure 9bAs shown, the first main winding 121, the first auxiliary winding 131, the second auxiliary winding 132 and the second main winding 122 are arranged in sequence, and the arrangement order is not limited thereto, and may also be arranged in the order of the first auxiliary winding 131, the first main winding 121, the second main winding 122 and the second auxiliary winding 132. No magnetic material is provided between each two windings, and only non-magnetic insulating material is provided. In this embodiment, the first end 121a of the first main winding 121 and the second end 122b of the second main winding 122 are disposed adjacent to the side surface 116c of the magnetic core, and the second end 121b of the first main winding 121 and the first end 122a of the second main winding 122 are disposed adjacent to the side surface 116d of the magnetic core; the first pin 121a of the first main winding 121 and the first pin 122a of the second main winding 122 extend toward the top surface 116a of the magnetic core 116, and the second pin 121b of the first main winding 121 and the second pin 122b of the second main winding 122 extend toward the bottom surface 116b of the magnetic core 116. Both pins of the first auxiliary winding 131 and the second auxiliary winding 132 extend toward the bottom surface 116b of the magnetic core 116. In this embodiment, there is a certain magnetic coupling between the first main winding 121 and the second main winding 122. When the two-phase integrated TLVR inductor 200e of this embodiment is used in a two-phase buck circuit, the two-phase buck circuit uses two control signals with a phase difference of 180 degrees, so that the DC magnetic flux generated by the two-phase main windings cancels each other, that is, the first main winding 121 and the second main winding 122 work in an anti-coupling state. Because of the characteristic of the DC magnetic flux canceling each other, the anti-coupling inductor improves the magnetic saturation current characteristic, thereby reducing the core loss and improving the power density of the inductor. Furthermore, the first auxiliary winding 131 and the first main winding 121 are coupled to each other, and the second auxiliary winding 132 and the second main winding 122 are coupled to each other, that is, the two main windings are in an anti-coupling working state and then the auxiliary winding is added to realize the TLVR technology, so that the equivalent dynamic inductance of the inductor is further reduced and the volume is further reduced; the voltage regulation module using the anti-coupling TLVR inductor further reduces the power loss and improves the power density of the module while obtaining better dynamic performance.

[0073] Figure 5a to Figure 5b , Figure 6a to Figure 6b , Figure 7a to Figure 7b as well as Figure 8a to Figure 8b Any one of the integrated molding processes or insulation technologies in the illustrated embodiments can be applied to Figures 9a to 9c The reverse-coupled TLVR inductor shown also has the technical features and benefits of the fourth to seventh embodiments, which will not be described in detail here.

[0074] In addition, the structures and insulation methods of all the embodiments disclosed in the present invention are applicable to the first type of pressing method of the inductor, that is, the direct hot pressing method.

[0075] The TLVR inductor described in the above embodiments can not only be applied to an independent voltage regulation module, but also can be a part of an electronic device as long as it meets the technical features and benefits disclosed by the present invention.

[0076] The “equal”, “same” or “equal” disclosed in the present invention all need to consider the parameter distribution of the project, and the error distribution is within ±30%; the definition of two line segments or two straight lines being “parallel” is that the angle between the two line segments or two straight lines is less than or equal to 45 degrees; the definition of phase “misalignment” also needs to consider the parameter distribution of the project, and the error distribution of the degree of misalignment is within ±30%.

[0077] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0078] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An integrally formed inductor, characterized in that: It includes a magnetic core, a first main winding, a first auxiliary winding and an insulating material; the first main winding and the first auxiliary winding are arranged adjacent to each other; the insulating material is arranged between the first main winding and the first auxiliary winding, and the insulating material is an insulating, non-magnetic and high-temperature resistant material.

2. The one-piece molded inductor according to claim 1, characterized in that: The magnetic core is composed of magnetic powder particles, and the magnetic powder particles, the first main winding, the first auxiliary winding and the insulating material are formed into the integrally formed magnetic core and the integrally formed inductor through a one-time pressing and annealing process; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

3. The one-piece molded inductor according to claim 1, characterized in that: The magnetic core is composed of magnetic powder particles, the magnetic powder particles and the first main winding are pressed once to form a first inductor blank, and the magnetic powder particles and the first auxiliary winding are pressed once to form a second inductor blank; the first inductor blank and the second inductor blank both include a bonding surface.

4. The one-piece molded inductor according to claim 3, characterized in that: The first main winding includes a first exposed surface, which is exposed on the bonding surface of the first inductor stock material, and is concave in the bonding surface of the first inductor stock material to form a groove, and the groove is used for coating and accommodating insulating material.

5. The one-piece molded inductor according to claim 4, characterized in that: The bonding surface of the first inductor blank and the bonding surface of the second inductor blank are bonded and assembled, and the magnetic core and the one-piece molded inductor are formed through secondary pressing and annealing processes; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

6. The one-piece molded inductor according to claim 4, characterized in that: The first auxiliary winding includes a second exposed surface, the second exposed surface is exposed to the bonding surface of the second inductor blank, and the insulating material is coated on the second exposed surface.

7. The one-piece molded inductor according to claim 6, characterized in that: The bonding surface of the first inductor blank and the bonding surface of the second inductor blank are bonded and assembled, and the magnetic core and the one-piece molded inductor are formed through secondary pressing and annealing processes; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

8. The one-piece molded inductor according to claim 1, characterized in that: It also includes a second main winding and a second auxiliary winding, wherein the second main winding and the second auxiliary winding are arranged adjacent to each other; the insulating material is also arranged between the second main winding and the second auxiliary winding; the first main winding, the insulating material, the first auxiliary winding, the second auxiliary winding, the insulating material and the second main winding are arranged in sequence.

9. The one-piece molded inductor according to claim 8, characterized in that: The magnetic core is composed of magnetic powder particles, and the magnetic powder particles and the first winding are pressed once to form a first inductor blank; the magnetic powder particles and the second winding are pressed once to form a second inductor blank; the magnetic powder particles, the first auxiliary winding and the second auxiliary winding are pressed once to form a third inductor blank; the first inductor blank, the second inductor blank and the third inductor blank all include a bonding surface.

10. The one-piece molded inductor according to claim 9, characterized in that: The first main winding includes a first exposed surface, which is exposed on the bonding surface of the first inductor stock material, and the first exposed surface is concave in the bonding surface of the first inductor stock material to form a groove, and the groove is used to coat and accommodate insulating material; the second main winding includes a second exposed surface, which is exposed on the bonding surface of the second inductor stock material, and the second exposed surface is concave in the bonding surface of the second inductor stock material to form a groove, and the groove is used to coat and accommodate insulating material.

11. The one-piece molded inductor according to claim 10, characterized in that: The bonding surface of the first inductor blank coated with insulating material and the bonding surface of the third inductor blank are bonded and assembled, and the bonding surface of the second inductor blank coated with insulating material and the bonding surface of the third inductor blank are bonded and assembled; the magnetic core and the one-piece molded inductor are formed by secondary pressing and annealing process; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

12. The one-piece molded inductor according to claim 8, characterized in that: The magnetic core is composed of magnetic powder particles, the first winding, the second winding and the magnetic powder particles are pressed together to form a first inductor blank, and the first auxiliary winding, the second auxiliary winding and the magnetic powder particles are pressed together to form a second inductor blank; the first inductor blank and the second inductor blank both include a first bonding surface and a second bonding surface; the first inductor blank is in a concave shape, and the second inductor blank is in an I shape.

13. The one-piece molded inductor according to claim 12, characterized in that: The first winding is exposed on the first bonding surface of the first inductor blank and is recessed in the first bonding surface to form a first groove; the second winding is exposed on the second combination surface of the second inductor blank and is recessed in the second combination surface to form a second groove; the first groove and the second groove are used for coating and accommodating insulating materials.

14. The one-piece molded inductor according to claim 13, characterized in that: The first bonding surface of the first inductor blank coated with insulating material is bonded to the first bonding surface of the second inductor blank, and the second bonding surface of the first inductor blank coated with insulating material is bonded and assembled to the second bonding surface of the second inductor blank; the magnetic core and the one-piece molded inductor are formed through secondary pressing and annealing processes; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

15. An integrally formed inductor, characterized in that: It comprises a magnetic core, a first main winding, a first auxiliary winding and an insulating material; the first main winding and the first auxiliary winding are arranged adjacent to each other; the insulating material covers the first auxiliary winding, and the insulating material is an insulating, non-magnetic and high temperature resistant material.

16. The one-piece molded inductor according to claim 15, characterized in that: The first auxiliary winding, the first main winding and the magnetic powder material coated with the insulating material are subjected to a pressing and annealing process to form the magnetic core and the one-piece molded inductor; the first main winding and the first auxiliary winding have the same geometric shape inside the magnetic core; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

17. The one-piece molded inductor according to claim 15, characterized in that: It also includes a second winding and a second auxiliary winding, the second main winding and the second auxiliary winding are arranged adjacent to each other; the insulating material covers the second auxiliary winding; the first main winding, the first auxiliary winding covered with the insulating material, the second auxiliary winding covered with the insulating material and the second main winding are arranged in sequence.

18. The one-piece molded inductor according to claim 17, characterized in that: The first auxiliary winding coated with insulating material, the first main winding, the second auxiliary winding coated with insulating material, the second winding and the magnetic powder material are pressed and annealed to form the magnetic core and the integrally formed inductor; the melting point temperature of the insulating material is higher than the annealing process temperature of the magnetic powder particles.

19. The one-piece molded inductor according to claim 1 or claim 15, characterized in that: The first winding includes a first pin and a second pin, and the first auxiliary winding includes a first pin and a second pin; the magnetic core includes a bottom surface and a top surface opposite to each other; the second pin of the first winding and the first pin and the second pin of the first auxiliary winding extend toward the bottom surface of the magnetic core.

20. The one-piece molded inductor according to claim 8 or claim 17, characterized in that: The first main winding and the second main winding both include a first pin and a second pin, and the first auxiliary winding and the second auxiliary winding both include a first pin and a second pin; the magnetic core includes relative top and bottom surfaces; the second pin of the first winding and the second pin of the second winding as well as the first pin and the second pin of the first auxiliary winding and the second auxiliary winding all extend toward the bottom surface of the magnetic core, and the first pin of the first main winding and the second main winding all extend toward the top surface of the magnetic core.

21. The one-piece molded inductor according to claim 20, characterized in that: The first pin of the first winding and the first pin of the second winding are disposed adjacent to the same side of the magnetic core, and the second pin of the first winding and the second pin of the second winding are disposed adjacent to the other side of the magnetic core.

22. The one-piece molded inductor according to claim 20, characterized in that: The first pin of the first winding and the second pin of the second winding are disposed adjacent to the same side of the magnetic core, and the second pin of the first winding and the first pin of the second winding are disposed adjacent to the other side of the magnetic core.

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