Integrally-formed fully-coupled TLVR inductor and preparation method thereof
Through the integrated molding of fully coupled TLVR inductor structure, the problem of high cost, large volume and high loss of TLVR inductor mold is solved by using iron-nickel alloy material and hot press forming process, and the effect of miniaturization and high efficiency of inductors is achieved.
Patent Information
- Application Number
- CN202510683315.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-26
- Publication Date
- 2025-08-12
AI Technical Summary
The core structure of the existing TLVR inductors leads to high mold production costs, and the uninsulated treatment before the dual coil assembly leads to increased product volume and power loss.
The integrated molded fully coupled TLVR inductive structure is adopted, and the E-type magnetic core is prepared using iron-nickel alloy material, and the primary coil and secondary coil are closely combined with the magnetic core through the hot press forming process, adding an insulating coating to avoid short circuits and reduce volume and loss.
Effectively reduce the inductor volume by about 20%, reduce power loss by about 20%, and improve magnetic saturation.
Smart Images
Figure CN120473302A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of inductors, and in particular to an integrally formed fully coupled TLVR inductor and a preparation method thereof. Background Art
[0002] Inductors are one of the most commonly used components in electronic devices, widely used in various circuits to achieve filtering, energy storage, matching, and resonance. As electronic products become increasingly miniaturized and portable, and as components are assembled in high-density configurations, the use of inductors has seen rapid growth.
[0003] TLVR inductors, or trans-inductor voltage regulations, typically use Mn-Zn ferrite materials to create T-shaped and U-shaped cores, which are then assembled with coupled dual coils. The magnetic saturation of Mn-Zn ferrite cores is low.
[0004] The magnetic core in the prior art adopts a T-shaped structure and a U-shaped structure. Therefore, different structures are also required for the corresponding molds, which leads to higher production costs of the molds. In addition, before being assembled with the coupled double coils, the double coils are not insulated. Therefore, in order to avoid short circuits caused by coil contact, the double coils need to be spaced apart, which will increase the overall volume of the product. Summary of the Invention
[0005] The main purpose of the present invention is to propose an integrally formed fully coupled TLVR inductor and a preparation method thereof, aiming to reduce the inductor volume, lower power loss, and improve magnetic saturation.
[0006] To achieve the above objectives, the present invention provides an integrally formed fully coupled TLVR inductor, comprising: a primary coil, a secondary coil, a first E-type magnetic core and a second E-type magnetic core with identical structures, wherein a positioning block for positioning the secondary coil is provided between the first E-type magnetic core and the second E-type magnetic core, a U-shaped positioning groove is provided in the middle part of the first E-type magnetic core and the second E-type magnetic core around the positioning block, an insulating coating is provided on the surface of the secondary coil, the secondary coil is fitted inside the primary coil, and the primary coil and the secondary coil are arranged in the U-shaped positioning groove.
[0007] A further technical solution of the present invention is that the primary coil is U-shaped, and two free ends of the primary coil extend outward to form a first pin and a second pin.
[0008] A further technical solution of the present invention is that the secondary coil is U-shaped, and the two free ends of the secondary coil extend inward to form a third pin and a fourth pin, and the first pin, the second pin, the third pin and the fourth pin are flush.
[0009] A further technical solution of the present invention is that the material of the first E-type magnetic core and the second E-type magnetic core is an iron-nickel alloy, or a mixed alloy with iron and nickel as the main body.
[0010] To achieve the above object, the present invention further provides a method for preparing an integrally formed fully coupled TLVR inductor. The method is applied to the integrally formed fully coupled TLVR inductor as described above, and the method comprises the following steps:
[0011] Step S10: prefabricate a mold with positioning blocks and U-shaped positioning grooves according to specifications and dimensions, fill the mold with iron-nickel alloy powder or mixed alloy powder mainly composed of iron and nickel, and mold and press to obtain the first E-type magnetic core and the second E-type magnetic core;
[0012] Step S20: selecting a conductive metal sheet and bending it into a U-shaped primary coil and a U-shaped secondary coil, inserting the primary coil and the secondary coil into the U-shaped positioning groove, positioning the primary and secondary coils using a positioning block, and positioning the primary coil using the U-shaped positioning groove, so that the secondary coil is fitted into the primary coil;
[0013] Step S30 : subjecting the first E-type magnetic core and the second E-type magnetic core to a hot pressing process with heating and pressurizing in a mold, so that the first E-type magnetic core and the second E-type magnetic core are melted into one piece to form a fully coupled TLVR inductor.
[0014] The beneficial effects of the one-piece fully coupled TLVR inductor and the preparation method of the present invention are:
[0015] The present invention, through the above technical solution, includes: a primary coil, a secondary coil, a first E-type magnetic core and a second E-type magnetic core with the same structure, a positioning block for positioning the secondary coil is provided in the middle of the first E-type magnetic core and the second E-type magnetic core, both sides of the first E-type magnetic core and the second E-type magnetic core extend upward to form positioning protrusions for positioning the primary coil, an E-shaped cavity is enclosed between the positioning block and the positioning protrusions, the surface of the secondary coil is provided with an insulating coating, the secondary coil is fitted in the primary coil, the primary coil and the secondary coil are arranged in the E-shaped accommodating cavity of the first E-type magnetic core and the second E-type magnetic core, and through a hot pressing process, the primary coil and the secondary coil are tightly fitted with the first E-type magnetic core and the second E-type magnetic core without gaps, which can effectively reduce the inductance volume, reduce power loss, and improve magnetic saturation, wherein the product size is reduced by about 20%, and the power loss of the product can also be reduced by about 20%. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. 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 the structures shown in these drawings without paying any creative work.
[0017] Figure 1 It is the overall structure of the preferred embodiment of the one-piece fully coupled TLVR inductor of the present invention;
[0018] Figure 2 It is a structural diagram of the secondary coil;
[0019] Figure 3 It is a structural diagram of the primary coil;
[0020] Figure 4 is a schematic structural diagram of the first E-type magnetic core;
[0021] Figure 5 Schematic diagram of the assembly of the first E-shaped magnetic core and the second E-shaped magnetic core.
[0022] Description of Figure Numbers:
[0023] Primary coil 1; secondary coil 2; first E-type magnetic core 3; second E-type magnetic core 4; positioning block 5; positioning slot 6; first pin 7; second pin 8; third pin 9; fourth pin 10.
[0024] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION
[0025] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.
[0026] The present invention proposes an integrated fully coupled TLVR inductor, such as Figures 1 to 5As shown, a preferred embodiment of the one-piece fully coupled TLVR inductor of the present invention includes: a primary coil 1, a secondary coil 2, a first E-type magnetic core 3 and a second E-type magnetic core 4 of identical structure. A positioning block 5 for positioning the secondary coil 2 is provided between the first E-type magnetic core 3 and the second E-type magnetic core 4. A U-shaped positioning groove 6 is formed in the middle portion of the first E-type magnetic core 3 and the second E-type magnetic core 4 around the positioning block 5. The surface of the secondary coil 2 is provided with an insulating coating. In this embodiment, the size of the primary coil 1 is slightly larger than that of the secondary coil 2. The secondary coil 2 is fitted inside the primary coil 1, and the primary coil 1 and the secondary coil 2 are disposed in the U-shaped positioning groove 6. In this embodiment, the size of the primary coil 1 is slightly larger than that of the secondary coil 2.
[0027] During assembly, the secondary coil 2 wraps around the positioning block 5, the U-shaped positioning groove 6 wraps around the primary coil 1, and the secondary coil 2 is arranged in close proximity to the primary coil 1, which not only limits the primary coil 1 and the secondary coil 2 to prevent them from moving, but also effectively reduces the volume of the entire inductor.
[0028] Furthermore, in this embodiment, the primary coil 1 is U-shaped, and two free ends of the primary coil 1 extend outward to form a first pin 7 and a second pin 8 .
[0029] The secondary coil 2 is U-shaped, and two free ends of the secondary coil 2 extend inward to form a third pin 9 and a fourth pin 10 . The first pin 7 , the second pin 8 , the third pin 9 and the fourth pin 10 are flush.
[0030] In this embodiment, the two free ends of the primary coil 1 are extended outward to form a first pin 7 and a second pin 8, and the two free ends of the secondary coil 2 are extended inward to form a third pin 9 and a fourth pin 10. In addition, the first pin 7, the second pin 8, the third pin 9 and the fourth pin 10 are arranged flush with each other, which can effectively avoid short circuit current at the pins.
[0031] Furthermore, in this embodiment, the material of the first E-type magnetic core 3 and the second E-type magnetic core 4 is an iron-nickel alloy, or a mixed alloy mainly composed of iron and nickel.
[0032] Compared with Mn-Zn ferrite materials, iron-nickel alloy materials have higher magnetic saturation characteristics, which can reduce product size by about 20% and reduce product power loss by about 20%.
[0033] When preparing the one-piece fully coupled TLVR inductor of the present invention, an iron-nickel alloy material or a mixed alloy with iron and nickel as the main body is first used to form two E-shaped structure magnetic cores, which are then assembled with coupled dual coils. Then, they are secondary molded in a mold using high temperature and high pressure to form a complete, air-gap-free, fully coupled dual inductor structure with a coupling coefficient of over 0.97.
[0034] In summary, the one-piece fully coupled TLVR inductor of the present invention adopts the above technical solution, including: a primary coil 1, a secondary coil 2, a first E-type magnetic core 3 and a second E-type magnetic core 4 with the same structure, a positioning block 5 for positioning the secondary coil 2 is provided in the middle of the first E-type magnetic core 3 and the second E-type magnetic core 4, and a U-shaped positioning groove 6 is provided around the positioning block 5 in the middle part of the first E-type magnetic core 3 and the second E-type magnetic core 4. The surface of the secondary coil 2 is provided with an insulating coating, and the secondary coil 2 is fitted in the primary coil 1. The primary coil 1 and the secondary coil 2 are arranged in the U-shaped positioning groove 6. Through the hot pressing forming process, the primary coil and the secondary coil are tightly matched with the first E-type magnetic core and the second E-type magnetic core without gaps, which can effectively reduce the volume of the inductor, reduce power loss, and improve magnetic saturation. Among them, the product size is reduced by about 20%, and the power loss of the product can also be reduced by about 20%.
[0035] To achieve the above objectives, the present invention further provides a method for preparing an integrally formed fully coupled TLVR inductor. The method is applied to the integrally formed fully coupled TLVR inductor described in the above embodiment, and the method comprises the following steps:
[0036] Step S10: prefabricate a mold corresponding to the magnetic core with positioning blocks 5 and U-shaped positioning grooves 6 according to specifications and dimensions, fill the mold with iron-nickel alloy powder, or mixed alloy powder with iron and nickel as the main body, and mold and press to obtain the first E-type magnetic core 3 and the second E-type magnetic core 4.
[0037] In step S20, a conductive metal sheet is selected and bent into a U-shaped primary coil 1 and a U-shaped secondary coil 2. The primary coil 1 and the secondary coil 2 are installed in the U-shaped positioning groove 6. The primary and secondary coils 2 are positioned by the positioning block 5, and the primary coil 1 is positioned by the U-shaped positioning groove 6. The secondary coil 2 is fitted into the primary coil 1.
[0038] In step S30, the first E-shaped magnetic core 3 and the second E-shaped magnetic core 4 are subjected to a hot pressing process in a mold by heating and pressurizing, so that the first E-shaped magnetic core 3 and the second E-shaped magnetic core 4 are melted into one piece to form a fully coupled TLVR inductor, wherein the coupling coefficient can reach above 0.97.
[0039] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made by using the contents of the present invention description and drawings under the concept of the present invention, or direct / indirect application in other related technical fields are included in the patent protection scope of the present invention.
Claims
1. An integrally formed fully coupled TLVR inductor, characterized in that: include: A primary coil, a secondary coil, a first E-type magnetic core and a second E-type magnetic core with the same structure, a positioning block for positioning the secondary coil is provided in the middle of the first E-type magnetic core and the second E-type magnetic core, a U-shaped positioning groove is provided in the middle part of the first E-type magnetic core and the second E-type magnetic core around the positioning block, an insulating coating is provided on the surface of the secondary coil, the secondary coil is fitted in the primary coil, and the primary coil and the secondary coil are provided in the U-shaped positioning groove.
2. The one-piece fully coupled TLVR inductor according to claim 1, characterized in that: The primary coil is U-shaped, and two free ends of the primary coil extend outward to form a first pin and a second pin.
3. The one-piece fully coupled TLVR inductor according to claim 2, characterized in that: The secondary coil is U-shaped, and two free ends of the secondary coil extend inward to form a third pin and a fourth pin. The first pin, the second pin, the third pin and the fourth pin are flush.
4. The one-piece fully coupled TLVR inductor according to claim 1, characterized in that: The material of the first E-shaped magnetic core and the second E-shaped magnetic core is an iron-nickel alloy, or a mixed alloy mainly composed of iron and nickel.
5. A method for preparing an integrally formed fully coupled TLVR inductor, characterized in that: The method is applied to the one-piece fully coupled TLVR inductor according to any one of claims 1 to 4, and the method comprises the following steps: Step S10: prefabricate a mold corresponding to the magnetic core with positioning blocks and U-shaped positioning grooves according to specifications and dimensions, fill the mold with iron-nickel alloy powder, or mixed alloy powder mainly composed of iron and nickel, and mold and press to obtain the first E-shaped magnetic core and the second E-shaped magnetic core; Step S20: selecting a conductive metal sheet and bending it into a U-shaped primary coil and a U-shaped secondary coil, inserting the primary coil and the secondary coil into the U-shaped positioning groove, positioning the primary and secondary coils using a positioning block, and positioning the primary coil using the U-shaped positioning groove, so that the secondary coil is fitted into the primary coil; Step S30 : subjecting the first E-type magnetic core and the second E-type magnetic core to a hot pressing process with heating and pressurizing in a mold, so that the first E-type magnetic core and the second E-type magnetic core are melted into one piece to form a fully coupled TLVR inductor.