Inductor capable of improving saturation characteristic

Abstract

The invention discloses an inductor capable of improving saturation characteristics, and particularly relates to the technical field of inductors, the inductor comprises an inductor shell, end electrodes are fixedly installed at the two ends of the inductor shell, and a vertical conductor mechanism is arranged in the inductor shell; the vertical conductor mechanism comprises two inner conductors, and the two inner conductors are both installed at the bottom of the inner wall of the inductor shell and are both electrically connected with the end electrodes. Through a vertical conductor mechanism, occupation of a side magnetic path by a traditional horizontal conductor is changed, and a magnetic circuit is optimized, so that under the same or smaller size of the inductor, the magnetic saturation resistance of the inductor is remarkably enhanced, the saturation current is improved, the saturation current of the inductor is improved, and the current distribution is optimized through parallel design of the inner conductor and the connecting conductor; the optimal design of the cross sectional area of the connecting conductor enables the total resistance after parallel connection to meet the requirement of low direct-current resistance, the direct-current resistance is greatly reduced, and the energy efficiency of the inductor is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of inductors. More specifically, the present invention relates to an inductor with improved saturation characteristics. Background Art

[0002] With the rapid development of electronic devices, the integration level of chips has been continuously improved, and their power consumption has also increased day by day. The demand for current continues to rise. Taking NVIDIA's gaming graphics cards as an example, from the GTX1080 in 2016 to the RTX4080 in 2022, the core power consumption has increased sharply from 180W to 450W, and the number of core power supply inductors has also increased significantly from 6 to 23. However, limited by market applications, the space for adjusting the area of the board is extremely limited, which requires the inductor to achieve higher performance in a limited space.

[0003] Existing inductors face many bottlenecks in improving performance. For example, for the Eaton FP1405R1-R120-R inductor, when the size is 14.0mm x 7.0mm x 5.0mm, the saturation current of the inductance value of 0.12uH is only 84A. Even when the height is increased to 5.2mm, the saturation current only increases to 8�A. The limitation of the side magnetic path makes the improvement effect of simply increasing the height on the saturation characteristics negligible. At the same time, the DC resistance of the existing inductor is 0.25mΩ, and the relatively high DC resistance leads to large DC losses and low energy efficiency. In addition, in terms of electromagnetic compatibility, as the electromagnetic environment inside electronic devices becomes more and more complex, existing inductors lack an effective shielding structure, are easily interfered by external stray magnetic fields, and the magnetic fields generated by themselves will also have an adverse impact on surrounding electronic components, reducing the stability of the entire electronic device system. In terms of heat dissipation, as the working power of the inductor increases, if the generated heat cannot be dissipated in time, it will cause the temperature of the inductor to rise, thereby affecting its performance and service life. Summary of the Invention

[0004] In order to overcome the above-mentioned defects of the prior art, the present invention provides an inductor with improved saturation characteristics to solve the problems raised in the above background art.

[0005] To achieve the above object, the present invention provides the following technical solution: An inductor with improved saturation characteristics, including an inductor housing, both ends of the inductor housing are fixedly installed with end electrodes, and a vertical conductor mechanism is arranged inside the inductor housing; The vertical conductor mechanism includes two inner conductors, both of the two inner conductors are installed at the bottom of the inner wall of the inductor housing, both of the two inner conductors are electrically connected to the end electrodes, and a connecting conductor is fixedly connected between the two inner conductors; The end electrode internally includes a first electrode layer, a second electrode layer, and a third electrode layer in sequence from outside to inside; Inside the inductor housing, from outside to inside in sequence, there are a ceramic dielectric layer, a shielding layer, and a braided shielding layer.

[0006] Preferably, the two inner conductors are connected in parallel through a connecting conductor. The vertical conductor mechanism formed by the inner conductors and the connecting conductor is conducive to the component insertion and welding operations during the production of the inductor, and at the same time optimizes the current distribution in the inductor, thereby improving the inductor performance.

[0007] Preferably, the inner conductors and the connecting conductor change the layout of the traditional horizontal conductors occupying the effective area of the side magnetic path. By setting the conductors vertically, the magnetic circuit is optimized, enabling the inductor to better resist magnetic saturation under the same volume or a smaller volume.

[0008] Preferably, the first electrode layer is specifically a silver electrode, the second electrode layer is specifically a nickel electrode, the third electrode layer is specifically a tin electrode, and the thicknesses of the first electrode layer, the second electrode layer, and the third electrode layer are all the same.

[0009] Preferably, the ceramic dielectric layer is made of a ceramic material with a high dielectric constant. The ceramic dielectric layer can enhance the constraint of the internal electric field of the inductor, improve the energy storage capacity of the inductor, and thus contribute to improving the saturation characteristics of the inductor.

[0010] Preferably, the shielding layer is made of a permalloy material with a high magnetic permeability. The shielding layer can effectively block the interference of external stray magnetic fields on the internal magnetic field of the inductor, stabilize the magnetic field environment in which the inductor operates, and enable the inductor to maintain good performance in a complex electromagnetic environment.

[0011] Preferably, the braided shielding layer is woven from metal wires. The braided shielding layer enhances the shielding effect against electromagnetic interference and has a certain flexibility. When the inductor is slightly impacted by external force, it can play a buffering and protective role to prevent damage to the internal structure.

[0012] Preferably, the cross-sectional area of the connecting conductor is optimized so that the total resistance after the two inner conductors are connected in parallel meets the requirement of low DC resistance. While ensuring uniform current distribution, the DC loss of the inductor is reduced, and the energy efficiency of the inductor is improved.

[0013] Preferably, a plurality of heat dissipation fins are fixedly installed on the top of the inductor housing, and the bottoms of the plurality of heat dissipation fins all penetrate the inductor housing and extend into the inductor housing.

[0014] Preferably, the heat dissipation fins are made of aluminum alloy, and a plurality of heat dissipation grooves are formed on the outer surface of the plurality of heat dissipation fins.

[0015] The technical effects and advantages of the present invention: 1. By setting up a vertical conductor structure, the occupation of the side magnetic path by the traditional horizontal conductor is changed, and the magnetic circuit is optimized. The inductor's ability to resist magnetic saturation is significantly enhanced under the same or smaller volume, and the saturation current is increased. The parallel design of the inner conductor and the connecting conductor optimizes the current distribution and reduces the DC resistance. The optimized design of the cross-sectional area of the connecting conductor ensures that the total resistance after parallel connection meets the low DC resistance requirement. The DC resistance is greatly reduced, the inductor energy efficiency is improved, and the trend of increasing chip power consumption and current demand is adapted to provide a stable power supply for high-power electronic equipment. 2. The shielding layer and braided shielding layer inside the inductor shell play an important role. The shielding layer is made of high-permeability Permalloy material, which effectively blocks external stray magnetic field interference and stabilizes the magnetic field environment inside the inductor. The braided shielding layer further enhances the shielding effect, and its flexibility can protect the internal structure when subjected to external force impact. This ensures that the inductor can still work stably in complex electromagnetic environments and possible external forces, reduces electromagnetic interference to surrounding electronic components, improves the electromagnetic compatibility and stability of the entire electronic equipment system, and ensures reliable operation of the equipment; 3. The use of high-dielectric-constant ceramic materials in the ceramic dielectric layer enhances the internal electric field constraint of the inductor, improves energy storage capacity, and helps improve the inductor saturation characteristics, providing more sufficient energy reserves for the inductor to operate stably in the circuit. This allows it to better maintain stable electromagnetic conversion when responding to current fluctuations and power changes, improving overall performance and meeting the high-performance requirements of electronic equipment for inductors. The aluminum alloy heat sink fins and heat sink slots on the top of the inductor shell greatly improve the heat dissipation effect. During operation, heat is quickly transferred to the heat sink fins and dissipated into the air through the increased heat dissipation area, reducing the inductor's operating temperature. A suitable operating temperature helps extend the inductor's service life, improve its reliability, reduce performance degradation and failure risks caused by overheating, and ensure that the inductor maintains stable performance during long-term use. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0017] Figure 2 It is a partial cross-sectional structural schematic diagram of the present invention.

[0018] Figure 3 It is a front cross-sectional structural schematic diagram of the present invention.

[0019] Figure 4 It is a schematic diagram of a partial cross-sectional structure of the present invention.

[0020] Figure 5 Schematic diagram of the internal structure of the inductor housing of the present invention.

[0021] Figure 6 For the present invention Figure 1Schematic diagram of the enlarged structure at A in the [original text, which seems to be Chinese but not fully shown here].

[0022] The reference numerals are: 1, inductor housing; 2, end electrode; 3, inner conductor; 4, connecting conductor; 5, first electrode layer; 6, second electrode layer; 7, third electrode layer; 8, ceramic dielectric layer; 9, shielding layer; 10, braided shielding layer; 11, heat dissipation fin; 12, heat dissipation groove. Specific embodiments

[0023] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0024] As shown in the attached Figures 1-6 An inductor for improving saturation characteristics, including an inductor housing 1, end electrodes 2 are fixedly installed at both ends of the inductor housing 1, and a vertical conductor mechanism is arranged inside the inductor housing 1; The vertical conductor mechanism includes two inner conductors 3, both of the two inner conductors 3 are installed at the bottom of the inner wall of the inductor housing 1, both of the two inner conductors 3 are electrically connected to the end electrode 2, and a connecting conductor 4 is fixedly connected between the two inner conductors 3; The end electrode 2 sequentially includes a first electrode layer 5, a second electrode layer 6, and a third electrode layer 7 from the outside to the inside; The inside of the inductor housing 1 sequentially includes a ceramic dielectric layer 8, a shielding layer 9, and a braided shielding layer 10 from the outside to the inside.

[0025] As shown in the attached Figures 3-5 As shown, the two inner conductors 3 are connected in parallel through the connecting conductor 4. The vertical conductor mechanism formed by the inner conductors 3 and the connecting conductor 4 is beneficial to the component insertion and welding operations during the production process of the inductor, and at the same time optimizes the current distribution in the inductor, thereby improving the inductor performance. The inner conductors 3 and the connecting conductor 4 change the layout of the traditional horizontal conductors occupying the effective area of the side magnetic path. By setting the conductors vertically, the magnetic circuit is optimized, so that the inductor can better resist magnetic saturation under the same volume or a smaller volume.

[0026] The external dimensions of the overall inductor have the following changes compared with the existing inductor: The length dimension is reduced from 14.0 mm of the existing inductor to 12 mm, and the reduction ratio is 14%.

[0027] The width dimension is reduced from 7.0 mm of the existing inductor to 6.4 mm, and the reduction ratio is 8.6%.

[0028] The height dimension increases from 5.2 mm of the existing inductor to 8.1 mm, with an increase ratio of 55.8%.

[0029] As shown in the Figures 1-5 attachment, the first electrode layer 5 is specifically a silver electrode, the second electrode layer 6 is specifically a nickel electrode, the third electrode layer 7 is specifically a tin electrode. The first electrode layer 5, the second electrode layer 6 and the third electrode layer 7 have the same thickness. The ceramic dielectric layer 8 is made of a ceramic material with a high dielectric constant. The ceramic dielectric layer 8 can enhance the confinement of the internal electric field of the inductor, improve the energy storage capacity of the inductor, and thus help to improve the saturation characteristics of the inductor. The shielding layer 9 is made of a permalloy material with a high magnetic permeability. The shielding layer 9 can effectively block the interference of external stray magnetic fields on the internal magnetic field of the inductor, stabilize the magnetic field environment in which the inductor works, so that the inductor can still maintain good performance in a complex electromagnetic environment. The braided shielding layer 10 is woven from metal wires. The braided shielding layer 10 enhances the shielding effect against electromagnetic interference and has a certain flexibility. When the inductor is slightly impacted by external force, it can play a buffering and protective role to prevent the internal structure from being damaged, ensuring the good shielding effect of the inductor housing 1.

[0030] As shown in the Figures 3-5 attachment, the cross-sectional area of the connecting conductor 4 is optimized so that the total resistance after the two inner conductors 3 are connected in parallel meets the requirement of low DC resistance. While ensuring uniform current distribution, the DC loss of the inductor is reduced, and the energy efficiency of the inductor is improved.

[0031] As shown in the Figure 1 、 2 3, 6, a plurality of heat dissipation fins 11 are fixedly installed on the top of the inductor housing 1. The bottoms of the plurality of heat dissipation fins 11 all penetrate through the inductor housing 1 and extend into the inductor housing 1. The heat dissipation fins 11 are made of aluminum alloy, and a plurality of heat dissipation grooves 12 are formed on the outer surface of the plurality of heat dissipation fins 11.

[0032] On the premise that the inductance value remains unchanged at 0.12 uH, the saturation current increases from 87 A of the existing inductor to 90 A, with an increase ratio of 3.4%.

[0033] The DC resistance DCR decreases from 0.25 mΩ of the existing inductor to 0.17 mΩ, with a decrease ratio of 32%.

[0034] Working principle of the present invention: Two inner conductors 3 are connected in parallel through a connecting conductor 4 to form a vertical conductor mechanism. From the perspective of the magnetic circuit, the traditional horizontal conductor layout is changed, and a vertical design is adopted, reducing the occupation of the effective area of the side magnetic path, optimizing the magnetic circuit. When current passes through the inner conductor 3 and the connecting conductor 4, the generated magnetic field distribution is more reasonable, enabling the inductor to better resist magnetic saturation and increase the saturation current under the same volume or a smaller volume. In terms of current distribution, the parallel structure evenly disperses the current, optimizing the current distribution in the inductor, reducing the loss caused by current concentration, thereby improving the inductor performance, meeting the requirements of low DC resistance DCR, and reducing DC loss; Inside the end electrode 2, from the outside to the inside, there are a silver electrode first electrode layer 5, a nickel electrode second electrode layer 6, and a tin electrode third electrode layer 7 in sequence. The silver electrode has good electrical conductivity, which can ensure a low-resistance connection between the inductor and the external circuit, reducing energy loss during signal transmission. The nickel electrode plays an intermediate transition and protection role, enhancing the stability of the electrode structure, preventing unnecessary chemical reactions between the silver electrode and the tin electrode, and at the same time improving the corrosion resistance of the electrode. The tin electrode is mainly used for welding, and its good welding performance facilitates the installation and fixation of the inductor on the circuit board, ensuring a reliable connection between the inductor and the circuit; The ceramic dielectric layer 8, the shielding layer 9, and the braided shielding layer 10 inside the inductor housing 1 work together. The ceramic dielectric layer 8 uses a ceramic material with a high dielectric constant, which can enhance the constraint of the internal electric field of the inductor, improve the energy storage capacity of the inductor, provide an energy basis for the stable operation of the inductor, and contribute to improving the saturation characteristics. The shielding layer 9 is made of a permalloy material with a high magnetic permeability, effectively blocking the interference of external stray magnetic fields on the internal magnetic field of the inductor, stabilizing the magnetic field environment for the inductor to work, and enabling the inductor to maintain good performance in a complex electromagnetic environment. The braided shielding layer 10 is woven from metal wires, further enhancing the shielding effect against electromagnetic interference. At the same time, its flexibility plays a buffering and protecting role when the inductor is slightly impacted by external force, preventing damage to the internal structure and ensuring the normal operation of the inductor; A plurality of heat dissipation fins 11 made of aluminum alloy are fixedly installed on the top of the inductor housing 1 and extend to the inside through the bottom of the inductor housing 1. When the inductor generates heat during operation, the heat is transferred to the heat dissipation fins 11 through conduction. The good thermal conductivity of the aluminum alloy material enables the heat to quickly spread on the heat dissipation fins 11. A plurality of heat dissipation grooves 12 are opened on the outer surface of the heat dissipation fins 11, increasing the contact area between the heat dissipation fins 11 and the air, accelerating the heat dissipation speed, thereby reducing the operating temperature of the inductor, ensuring the inductor to operate stably within an appropriate temperature range, and improving the reliability and service life of the inductor.

[0035] The following points should be noted: First, in the description of this application, it should be noted that unless otherwise specified and defined, the terms "installed", "connected", and "coupled" should be understood in a broad sense, which can be a mechanical connection or an electrical connection, or the communication inside two components, and can be directly connected. The terms "upper", "lower", "left", "right", etc. are only used to represent the relative position relationship. When the absolute position of the object being described changes, the relative position relationship may change; Second: In the attached drawings of the disclosed embodiments of the present invention, only the structures related to the disclosed embodiments are involved. For other structures, reference can be made to the general design. Without conflict, the same embodiment and different embodiments of the present invention can be combined with each other; Finally: The above are only the preferred embodiments of the present invention and are not used to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An inductor for improving saturation characteristics, comprising an inductor housing (1), characterized in that: Both ends of the inductor housing (1) are fixedly installed with end electrodes (2), and a vertical conductor mechanism is arranged inside the inductor housing (1). The vertical conductor mechanism includes two inner conductors (3), both of the two inner conductors (3) are installed at the bottom of the inner wall of the inductor housing (1), both of the two inner conductors (3) are electrically connected to the end electrodes (2), and a connecting conductor (4) is fixedly connected between the two inner conductors (3). The inside of the end electrode (2) includes a first electrode layer (5), a second electrode layer (6) and a third electrode layer (7) in sequence from outside to inside. The inside of the inductor housing (1) includes a ceramic dielectric layer (8), a shielding layer (9) and a braided shielding layer (10) in sequence from outside to inside.

2. The inductor for improving saturation characteristics according to claim 1, characterized in that: The two inner conductors (3) are connected in parallel through the connecting conductor (4), and the vertical conductor mechanism formed by the inner conductors (3) and the connecting conductor (4) is beneficial to the component insertion and welding operations during the production of the inductor, and at the same time optimizes the current distribution in the inductor, thereby improving the inductor performance.

3. The inductor for improving saturation characteristics according to claim 1, wherein: The inner conductors (3) and the connecting conductor (4) change the layout of the traditional horizontal conductors occupying the effective area of the side magnetic path. By setting the conductors vertically, the magnetic circuit is optimized, so that the inductor can better resist magnetic saturation under the same volume or a smaller volume.

4. The inductor for improving saturation characteristics according to claim 1, characterized in that: The first electrode layer (5) is specifically a silver electrode, the second electrode layer (6) is specifically a nickel electrode, the third electrode layer (7) is specifically a tin electrode, and the thicknesses of the first electrode layer (5), the second electrode layer (6) and the third electrode layer (7) are the same.

5. The inductor for improving saturation characteristics according to claim 1, characterized in that: The ceramic dielectric layer (8) is made of a ceramic material with a high dielectric constant. The ceramic dielectric layer (8) can enhance the constraint of the internal electric field of the inductor, improve the energy storage capacity of the inductor, and thus help to improve the saturation characteristics of the inductor.

6. The inductor for improving saturation characteristics according to claim 1, characterized in that: The shielding layer (9) is made of a permalloy material with a high magnetic permeability. The shielding layer (9) can effectively block the interference of external stray magnetic fields on the internal magnetic field of the inductor, stabilize the magnetic field environment in which the inductor works, so that the inductor can still maintain good performance in a complex electromagnetic environment.

7. The inductor for improving saturation characteristics according to claim 1, wherein: The braided shielding layer (10) is woven from metal wires. The braided shielding layer (10) enhances the shielding effect against electromagnetic interference, and has a certain flexibility. When the inductor is slightly impacted by external force, it can play a buffering and protecting role to prevent the internal structure from being damaged.

8. The inductor for improving saturation characteristics according to claim 1, wherein: The cross-sectional area of the connecting conductor (4) is optimized, so that the total resistance after the two inner conductors (3) are connected in parallel meets the requirement of low DC resistance. While ensuring uniform current distribution, the DC loss of the inductor is reduced, and the energy efficiency of the inductor is improved.

9. The inductor for improving saturation characteristics according to claim 1, characterized in that: A plurality of heat dissipation fins (11) are fixedly installed on the top of the inductor housing (1), and the bottoms of the plurality of heat dissipation fins (11) all penetrate the inductor housing (1) and extend into the inductor housing (1).

10. The inductor for improving saturation characteristics according to claim 9, characterized in that: The heat dissipation fins (11) are made of aluminum alloy, and a plurality of heat dissipation grooves (12) are opened on the outer surface of the plurality of heat dissipation fins (11).

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