Multiphase integrated inductor and preparation method thereof

Abstract

The invention provides a multiphase integrated inductor and a preparation method thereof, and belongs to the technical field of inductors. The multiphase integrated inductor comprises at least two inductor monomers, at least one common magnetic core and at least one outer framework; each inductor single body is composed of a center pillar magnetic core, a yoke magnetic core, a coil and an inner framework, and the magnetic conductivity of the common magnetic core is higher than that of the center pillar magnetic core and not lower than that of the yoke magnetic core; and the inductor monomers are tightly adhered to the at least one common magnetic core. The preparation method comprises the following steps: S1, prefabricating the assembly; s2, assembling the inductor monomers; s3, baking the inductor monomers; s4, preparing a semi-finished product; and S5, baking and curing. The multi-phase inductor has the advantages that compared with a plurality of inductors which are independently installed in a traditional technical scheme, integration of the multi-phase inductor is achieved, the overall size of the inductor is remarkably reduced, and miniaturization of circuits and electronic equipment is facilitated; meanwhile, due to the design of the common magnetic core, the total magnetic core consumption of the inductor is reduced, and the product cost is effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of inductor technology, and in particular to a multiphase integrated inductor and its fabrication method. Background Technology

[0002] Inductors are widely used in various electronic devices, serving functions such as filtering high-frequency electromagnetic signals. Currently, many power supply circuit designs require multiple inductors connected in parallel, such as three-phase AC inverter circuits and multi-phase parallel high-power boost circuits. Most current solutions use a single inductor for each phase / phase. However, with the technological upgrades in downstream application industries such as new energy vehicles and photovoltaic energy storage, miniaturization and integration of electronic devices have become urgent development requirements. Using multiple independent inductors in multi-phase parallel circuits undoubtedly occupies more space and is detrimental to circuit miniaturization. Developing multi-phase integrated miniaturized inductors is the technical solution to meet the miniaturization requirements of electronic devices. Summary of the Invention

[0003] To address the above technical problems, this invention provides a multiphase integrated inductor; furthermore, it also provides a method for fabricating a multiphase integrated inductor.

[0004] The technical problem solved by this invention can be achieved by the following technical solutions:

[0005] A multiphase integrated inductor, comprising:

[0006] The inductor comprises at least two individual inductors, at least one common magnetic core, and at least one outer frame; each individual inductor consists of a central core, a yoke core, a coil, and an inner frame, wherein the permeability of the common core is higher than that of the central core and not lower than that of the yoke core; each individual inductor is tightly bonded to at least one of the common cores.

[0007] Preferably, the coil is wound around the central core of the inductor, and the upper and lower end faces of the central core are respectively bonded to the middle area of ​​the two yoke cores.

[0008] Preferably, at least one side of the two yoke cores of the inductor is tightly bonded to the common core; the central cores of different inductor units are parallel to each other.

[0009] Preferably, the outer frame is disposed at both ends of the multiphase integrated inductor; the outer frame is provided with a receiving groove for accommodating the yoke iron core and the common core, and a limiting post for limiting the position of the coil lead-out.

[0010] Preferably, the inner frame is located between the yoke ferromagnetic core and the coil of the inductor unit; the inner frame has a through hole for the central column ferromagnetic core to pass through and define its position, and a positioning boss for defining the position of the yoke ferromagnetic core.

[0011] Preferably, the central core is one of a metal powder core, an amorphous magnetic powder core, a nanocrystalline magnetic powder core, an amorphous ribbon core, or a nanocrystalline ribbon core.

[0012] Preferably, the yoke ferromagnetic core is one of the following: metal powder core, amorphous magnetic powder core, nanocrystalline magnetic powder core, ferrite, amorphous ribbon magnetic core, and nanocrystalline ribbon magnetic core.

[0013] Preferably, the common magnetic core is one of the following: metal powder core, amorphous magnetic powder core, nanocrystalline magnetic powder core, ferrite, amorphous ribbon magnetic core, and nanocrystalline ribbon magnetic core.

[0014] Preferably, at least one of the yoke core and the common core is an amorphous ribbon core or a nanocrystalline ribbon core.

[0015] Preferably, an air gap may be selectively provided between the yoke core and the central core.

[0016] Preferably, the central core is a single complete core or is formed by bonding two or more cores with the same cross-section.

[0017] An insulating layer is also attached to the outer ring side of the central column magnetic core.

[0018] This invention also provides a method for fabricating a multiphase integrated inductor, comprising:

[0019] S1. Component prefabrication: The coil, central core, yoke core, common core, outer frame and inner frame are prefabricated according to the preset dimensions.

[0020] S2. Inductor unit assembly: Using an assembly fixture, the coil, central core, yoke core and inner frame prefabricated in step S1 are bonded and combined to obtain an inductor unit pre-assembled body.

[0021] S3. Baking of inductor monomers: Place the assembly fixture and the inductor monomer pre-assembly together in an oven or tunnel oven and bake at a predetermined temperature for a predetermined time. After the adhesive has cured, remove the assembly fixture to obtain the inductor monomer.

[0022] S4. Semi-finished product preparation: Using the outer frame, a predetermined number of the inductor units are bonded and combined with the common magnetic core to obtain the inductor semi-finished product;

[0023] S5. Baking and curing: The inductor semi-finished product prepared in step S4 is placed in an oven or tunnel furnace and baked at a predetermined temperature for a predetermined time to cure the adhesive, and finally the multiphase integrated inductor is obtained.

[0024] Preferably, at least one of the yoke core and the common core is the amorphous ribbon core or the nanocrystalline ribbon core.

[0025] Preferably, the amorphous ribbon magnetic core is formed by stacking amorphous ribbons and bonding adjacent amorphous ribbons with insulating adhesive; the nanocrystalline ribbon magnetic core is formed by stacking nanocrystalline ribbons and bonding adjacent nanocrystalline ribbons with insulating adhesive.

[0026] The amorphous ribbon core and the nanocrystalline ribbon core are both laid out in the same direction with no gaps inside the core.

[0027] Preferably, in step S2, the assembly fixture includes:

[0028] A C-shaped fixed frame is provided with two parallel bottom plates and a top plate, and a baffle that vertically connects the bottom plates and the top plate;

[0029] A length adjustment device is provided on the top plate of the C-shaped fixed frame.

[0030] Preferably, in steps S2, S3 and S4, performance tests are also required on the bonded inductor monomer pre-assembly, the inductor monomer and the inductor semi-finished product respectively.

[0031] Preferably, the multiphase integrated inductor can also be used by connecting electronic wires at the coil ends, depending on the application scenario.

[0032] Preferably, the multiphase integrated inductor can also be installed in a housing and potted with thermally conductive adhesive after connecting electronic wires to the coil ends, according to the needs of the application scenario.

[0033] The technical solution of this invention utilizes a modular design, employing a shared magnetic core with high permeability to integrate multiple inductor units into a compact whole, thereby achieving magnetic circuit closure for each phase of the inductor unit and effectively preventing the radiated magnetic field from each phase of the inductor during operation. Because the shared magnetic core has higher permeability than the central core, this technical solution achieves good decoupling between the phases of the integrated inductor, allowing each inductor unit to be integrated together without affecting its independent operation.

[0034] The beneficial effects of the technical solution of the present invention are as follows: compared with the multiple independently installed inductors used in the traditional technical solution, the technical solution of this invention realizes the integration of multi-phase inductors, significantly reduces the overall volume of the inductor, and is conducive to the miniaturization of circuits and electronic devices; at the same time, due to the design of the shared magnetic core, the technical solution of this invention reduces the total amount of magnetic core used in the inductor, and also effectively reduces the product cost. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the overall structure of a multiphase integrated inductor in a preferred embodiment of the present invention;

[0036] Figure 2 A schematic diagram of the skeleton breakdown of a multiphase integrated inductor is shown in a preferred embodiment of the present invention.

[0037] Figure 3 This is a schematic diagram of the structure of a multiphase integrated inductor (excluding the frame) in a preferred embodiment of the present invention;

[0038] Figure 4 This is a split-explosion diagram of a multiphase integrated inductor (excluding the frame) in a preferred embodiment of the present invention.

[0039] Figure 5 This is a schematic diagram of the splitting and explosion of another structure of an inductor cell in a preferred embodiment of the present invention;

[0040] Figure 6 This is a schematic diagram of a shared magnetic core stacking method in a preferred embodiment of the present invention;

[0041] Figure 7 This is a schematic diagram of the process for fabricating a multiphase integrated inductor in a preferred embodiment of the present invention;

[0042] Figure 8 This is a schematic diagram of the structure of the inductor unit after assembly with the assembly fixture, which is a preferred embodiment of the present invention.

[0043] Explanation of reference numerals in the attached figures:

[0044] 1. Inductor unit; 11. Center core; 12. Yoke core; 13. Coil; 14. Insulation layer; 2. Common core; 21. Soft magnetic alloy strip; 3. Outer frame; 31. Receiving groove; 32. Inner frame; 321. Through hole; 322. Positioning boss; 4. Assembly fixture; 41. Baffle; 42. Base plate; 43. Top plate; 44. Length adjustment device. Detailed Implementation

[0045] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0046] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0047] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the scope of the invention.

[0048] See Figures 1-4 In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, a multiphase integrated inductor is provided, comprising:

[0049] The inductor has at least two individual inductors 1, at least one common magnetic core 2, and at least one outer frame 3. The individual inductor 1 is composed of a central core 11, a yoke core 12, a coil 13, and an inner frame 32. The permeability of the common core 2 is higher than that of the central core 11 and not lower than that of the yoke core 12. The individual inductor 1 is tightly bonded to at least one common magnetic core 2.

[0050] Specifically, in this embodiment, the technical solution of the present invention uses a modular design to integrate multiple inductor units into a compact whole by utilizing a shared magnetic core with high permeability, and achieves magnetic circuit closure for each phase inductor unit, effectively preventing the inductors from radiating magnetic fields during operation. Because the shared magnetic core has higher permeability than the central core, this technical solution achieves good decoupling between the phases of the integrated inductor, allowing each inductor unit to be integrated together without affecting its independent operation.

[0051] Meanwhile, compared with the multiple independently installed inductors used in traditional technical solutions, this technical solution achieves the integration of multi-phase inductors, significantly reducing the overall size of the inductor and facilitating the miniaturization of circuits and electronic devices; at the same time, due to the shared magnetic core design, this technical solution reduces the total amount of magnetic core used in the inductor, which also effectively reduces product costs.

[0052] In this embodiment, inductor 1 is a single inductor element used to store electrical energy and filter high-frequency electromagnetic signals generated in the circuit.

[0053] The common magnetic core 2 is the core part located between the individual inductor units 1. It is used to connect the individual inductor units 1 into a whole and close the magnetic circuit of each individual inductor unit 1, so as to prevent the electromagnetic field radiated to the outside when the inductor is working and affect other electromagnetic devices. At the same time, since the permeability of the common magnetic core 2 is higher than that of the central core 11 of each individual inductor unit, it also effectively decouples the individual inductor units 1, avoids the mutual influence of the magnetic circuits of each individual inductor unit 1, and realizes that the individual inductor units 1 are integrated together, but each works independently.

[0054] In this embodiment, the multiphase integrated inductor includes a common magnetic core 2 and four inductor cells 1. The inductor cells 1 are fixed in pairs on both sides of the common magnetic core 2. The upper and lower ends of the combination of the common magnetic core 2 and the inductor cells 1 are provided with matching outer frames 3. Multiple common magnetic cores 2 can be provided according to actual needs. Taking the above-mentioned combination of one common magnetic core 2 and four inductor cells 1 as an example, another set or more sets of common magnetic cores 2 and inductor cells 1 can be attached to the small cross-section side of the common magnetic core 2.

[0055] In a preferred embodiment, at least one side of the two yoke cores 12 of the inductor 1 is tightly bonded to the common core 2; the central cores 11 of different inductor 1 are parallel to each other.

[0056] Preferably, one side of each of the two yoke cores 12 of each inductor unit 1 can be bonded to the common core 2 with insulating adhesive.

[0057] In a preferred embodiment, such as Figure 1 , Figure 2 , Figure 4 and Figure 5 As shown, the outer frame 3 is located at both ends of the multiphase integrated inductor; the outer frame 3 is provided with a receiving groove 31 for accommodating the yoke ferromagnetic core 12 and the common magnetic core 2, and is provided with a limiting post for limiting the output position of the coil 13.

[0058] The inner frame 32 is located between the yoke iron core 12 and the coil 13 of the inductor unit 1; the inner frame 32 has a through hole 321 through which the central column core 11 can pass and define its position, and a positioning boss 322 defining the position of the yoke iron core 12.

[0059] Specifically, in this embodiment, the multiphase integrated inductor also includes an outer frame 3 for fixing each component, which is disposed outside the upper and lower yoke ferromagnetic cores 12. The outer frame 3 is provided with a number of receiving slots 31 corresponding to the number of yoke ferromagnetic cores 12. The receiving slots 31 can respectively wrap the upper four yoke ferromagnetic cores 12 and the lower four yoke ferromagnetic cores 12 and restrict the yoke ferromagnetic cores 12 to a specific area to prevent changes in position from affecting the performance parameters after adjustment.

[0060] More specifically, in this embodiment, an inner frame 32 is provided between the yoke core 12 and the coil 13. The outer contour of the inner frame 32 matches the size of the yoke core 12. A through hole 321 is provided at the center of the inner frame 32. The size of the through hole 321 matches the size of the central core 11. Two positioning bosses 322 are provided on opposite sides of the outer contour of the inner frame 32. The yoke core 12 can be fitted between the positioning bosses 322 to realize the assembly of the inner frame 32 and the yoke core 12. In addition, during assembly, the central core 11 can pass through the through hole 321 and bond with the yoke core 12 to ensure that the central core 11 is located in the center of the yoke core 12.

[0061] In a preferred embodiment, the central core 11 is one of a metal powder core, an amorphous magnetic powder core, a nanocrystalline magnetic powder core, an amorphous ribbon core, or a nanocrystalline ribbon core.

[0062] In a preferred embodiment, the yoke ferromagnetic core 12 is one of a metal powder core, an amorphous magnetic powder core, a nanocrystalline magnetic powder core, a ferrite core, an amorphous ribbon core, or a nanocrystalline ribbon core.

[0063] In a preferred embodiment, the common magnetic core 2 is one of the following: metal powder core, amorphous magnetic powder core, nanocrystalline magnetic powder core, ferrite, amorphous ribbon magnetic core, and nanocrystalline ribbon magnetic core.

[0064] As a preferred embodiment, the aforementioned metal powder core includes iron-silicon powder core, iron-silicon-aluminum powder core, iron-nickel powder core, iron-silicon-nickel powder core, iron-silicon-aluminum-nickel powder core, and iron powder core.

[0065] In a preferred embodiment, at least one of the yoke core 12 and the common core 2 is an amorphous ribbon core or a nanocrystalline ribbon core.

[0066] Specifically, in this embodiment, the amorphous nanocrystalline ribbon has the characteristics of high magnetic permeability and low loss. By selectively setting the yoke iron core 12 and the common core 2 as either amorphous ribbon cores or nanocrystalline ribbon cores, the overall performance of the product can be further improved, and good decoupling between the inductor units 1 can be ensured.

[0067] In a preferred embodiment, the amorphous ribbon magnetic core is formed by stacking amorphous ribbons and bonding adjacent amorphous ribbons together with insulating adhesive; the nanocrystalline ribbon magnetic core is formed by stacking nanocrystalline ribbons and bonding adjacent nanocrystalline ribbons together with insulating adhesive.

[0068] Specifically, in this embodiment, at least one of the common magnetic core 2 and the yoke core 12 is an amorphous ribbon core or a nanocrystalline ribbon core. When the common magnetic core 2 is a ribbon core, the plane containing the ribbon is parallel to the axial direction of the central core 11 and perpendicular to the bonding surface between the yoke core and the common core; when the yoke core 12 is a ribbon core, the plane containing the ribbon is parallel to the axial direction of the central core 11 and perpendicular to the bonding surface between the yoke core and the common core, so that a complete magnetic circuit can be formed inside the inductor and the loss of the ribbon core is minimized.

[0069] In this embodiment, multiple inductor cells 1 are symmetrically arranged on both sides of the common magnetic core 2.

[0070] The inductor unit 1 includes multiple units. The specific number of inductor units 1 can be selected and combined according to actual needs. For example, 2, 3, 4 or other numbers of inductor units 1 can be selected. When there are many inductor units 1, multiple common magnetic cores 2 can be selected. The common magnetic cores 2 are connected in pairs on the small cross-section side and the corresponding number of inductor units 1 are set on the large cross-section side to form a multiphase integrated inductor.

[0071] This embodiment takes an inductor group composed of four individual inductors 1 as an example. Two individual inductors 1 are respectively provided at both ends of the common magnetic core 2, and they are symmetrically distributed. All four individual inductors 1 can be bonded to the common magnetic core 2 with adhesive.

[0072] In a preferred embodiment, such as Figure 6 As shown, the plane containing the soft magnetic alloy strip 21 is parallel to the axial direction of the central core 11.

[0073] In a preferred embodiment, such as Figure 4 As shown, the central core 11 can be a complete core; as Figure 5 As shown, the central core 11 can also be formed by bonding two (but not limited to) cores with the same cross-section to improve the anti-saturation capability of the central core 11.

[0074] In a preferred embodiment, an air gap may be optionally provided between the central core 11 and the yoke core 12.

[0075] Specifically, in this embodiment, the multiphase integrated inductor can open air gaps at multiple points as needed, such as between the central core 11 and the yoke core 12 or inside the central core 11 composed of multiple core segments, in order to reduce core loss and increase the core's anti-saturation performance.

[0076] In a preferred embodiment, an insulating isolation layer 14 is also provided on the outer ring side of the central core 11.

[0077] Specifically, in this embodiment, an insulating isolation layer 14 is also provided on the outer ring side of the central core 11. The insulating isolation layer 14 is located between the central core 11 and the coil 13. The insulating isolation layer 14 can be high-temperature tape, Nomi paper or similar materials. First, it plays the role of insulation protection, enhancing the insulation performance between the central core 11 and the coil 13. Second, the insulating isolation layer 14 still has stability in high-temperature environment, ensuring the normal operation of the device.

[0078] This invention also provides a method for fabricating a multiphase integrated inductor, such as... Figure 7 As shown, it includes:

[0079] S1. Component prefabrication: The coil 13, the central core 11, the yoke core 12, the common core 2, the outer frame 3 and the inner frame 32 are prefabricated according to the preset dimensions.

[0080] S2. Inductor unit 1 assembly: Using the assembly fixture 4, the coil 13, the central core 11, the yoke core 12 and the inner frame 32 prefabricated in step S1 are bonded together to obtain the inductor unit pre-assembly.

[0081] S3. Baking of inductor monomer 1: Place the assembly fixture 4 from step S2 and the inductor monomer pre-assembly together in an oven or tunnel oven, bake at a predetermined temperature for a predetermined time, and remove the assembly fixture 4 after the adhesive has cured to obtain inductor monomer 1.

[0082] The baking temperature is 100℃-150℃, and the baking time is 1-2 hours.

[0083] S4. Semi-finished product preparation: Using the outer frame 3, a predetermined number of inductor units 1 are bonded to the common magnetic core 2 to obtain the inductor semi-finished product.

[0084] S5. Baking and curing: The inductor semi-finished product prepared in step S4 is placed in an oven or tunnel furnace and baked at a predetermined temperature for a predetermined time to cure the adhesive and finally obtain the multiphase integrated inductor.

[0085] The baking temperature is 100℃-150℃, and the baking time is 1-2 hours.

[0086] In a preferred embodiment, step S2, the assembly fixture 4 includes:

[0087] A C-shaped fixed frame is provided with two parallel bottom plates 42 and top plates 43, and a baffle 41 that vertically connects the bottom plates 42 and top plates 43.

[0088] A length adjustment device 44 is provided on the top plate 43 of the C-shaped fixed frame.

[0089] Specifically, in this embodiment, the two yoke ferromagnetic cores 12 of the inductor unit 1 are respectively disposed at both ends of the central column core 11 on which the coil 13 is sleeved. During assembly, the two yoke ferromagnetic cores 12 are placed facing the top plate 43 and the bottom plate 42 respectively. The two yoke ferromagnetic cores 12 abut against the bottom plate 42 and one end of the length adjustment device 44 respectively. One side of the inductor unit 1 is attached to the baffle 41, so that the inductor unit 1 is fixed on the assembly fixture 4.

[0090] The length adjustment device 44 and the base plate 42 may be equipped with partitions to prevent direct contact with the yoke core 12. The partitions are made of flexible materials, such as epoxy board, to reduce damage to the core caused by the metal length adjustment device 44 and the base plate 42. The length adjustment device 44 can be, for example, Figure 8 The spiral assembly shown has an external thread on its main body and a hole on the corresponding top plate 43. The inner wall of the hole has an internal thread. The threaded connection enables the adjustment of the distance between the end of the length adjustment device 44 and the bottom plate 42, thereby enabling the physical pressing and tightness adjustment of the area where the insulating glue is applied to each magnetic core assembly in the inductor unit 1.

[0091] In a preferred embodiment, in steps S2, S3 and S4, performance tests are also performed on the bonded inductor monomer 1 and the inductor semi-finished product respectively.

[0092] Specifically, the inductor unit 1 uses the length adjustment device 44 of the assembly fixture 4 to adjust the tightness of the connection between each magnetic component to match the performance requirements. The inductor semi-finished product can also use a similar assembly fixture 4 for performance debugging. For example, the length adjustment device 44 is set on the end of the yoke core 12 away from the common core 2. The contact surface between the length adjustment device 44 and the yoke core 12 is adjusted according to actual needs to fit and abut against the outer side of the four yoke cores 12 on the same side. The length adjustment device 44 can adjust the tightness between the yoke core 12 and the common core 2 to meet different performance requirements.

[0093] Example 1

[0094] In this embodiment, the multiphase integrated inductor includes a common magnetic core 2, four inductor cells 1 arranged symmetrically in pairs on both sides of the common magnetic core 2, and an outer frame 3 disposed on the upper and lower sides of the assembly formed by the common magnetic core 2 and the four inductor cells 1. Each inductor cell 1 includes a central core 11, a coil 13 wound on the central core 11, and two yoke iron cores 12 respectively disposed at the upper and lower ends of the central core 11. The upper and lower ends of the central core are bonded to the middle area of ​​the yoke iron cores 12, and each of the two yoke iron cores 12 has one side tightly bonded to the common magnetic core 2. The multiphase integrated inductor in this embodiment has a design size of 62×50×53mm. The central core 11 and the yoke iron cores 12 are both made of Fe-Si magnetic powder core (permeability 60), and the common magnetic core is made of Fe-Si-B amorphous ribbon core (permeability 2000). The stacking direction of the internal ribbon is as follows. Figure 6 As shown, the coil is wound vertically with flat wire, specifically including the following steps:

[0095] S1. Component prefabrication: The coil 13, the central core 11, the yoke core 12, the common core 2, the outer frame 3 and the inner frame 32 are prefabricated according to the preset dimensions.

[0096] Among them, the central core 11 has a size of φ15mm×39mm, the yoke core 12 has a size of 20mm×7mm×23mm, the common core 2 has a size of 50mm×53mm×10mm, and the coil 13 with 38 turns is wound by flat wire vertical winding (the enameled wire is copper wire with a cross-section of 4.0mm×0.8mm).

[0097] S2. Inductor unit 1 assembly: Using the assembly fixture 4, the coil 13, the central core 11, the yoke core 12 and the inner frame 32 prefabricated in step S1 are bonded together to obtain the inductor unit pre-assembly.

[0098] S3. Baking of inductor monomer 1: Place the assembly fixture 4 from step S2 and the inductor monomer pre-assembly together in an oven or tunnel oven, bake at a predetermined temperature for a predetermined time, and remove the assembly fixture 4 after the adhesive has cured to obtain inductor monomer 1.

[0099] The baking temperature is 120℃ and the baking time is 1 hour.

[0100] S4. Semi-finished product preparation: Using the outer frame 3, the four inductor units 1 are respectively bonded to the common magnetic core 2 to obtain the inductor semi-finished product;

[0101] Among them, the four inductor units 1 are bonded to both sides of the common magnetic core 2 in pairs;

[0102] S5. Baking and curing: The inductor semi-finished product prepared in step S4 is placed in an oven or tunnel furnace and baked at a predetermined temperature for a predetermined time to cure the adhesive and finally obtain the multiphase integrated inductor.

[0103] The baking temperature was 120℃ and the baking time was 1 hour, resulting in a multiphase integrated inductor with dimensions of 62mm×50mm×53mm.

[0104] The inductor product of Example 1 was tested. Its inductance was measured at 66kHz / 1V using an impedance analyzer, and its loss was measured at 66kHz / 7.2A using a BH analyzer. The measured inductor performance parameters are shown in Table 1 below.

[0105] Example 2

[0106] In this embodiment, the structure and related dimensional parameters of the multiphase integrated inductor are consistent with those in Embodiment 1. Specifically, in this embodiment, the central core 11 and the yoke core 12 are made of Fe-Si magnetic powder core (permeability 60), and the common core is made of Fe-Si-Al magnetic powder core (permeability 90). The multiphase integrated inductor of the same specifications is prepared using the same preparation method as in Embodiment 1.

[0107] The inductor product was tested under the same test conditions as in Example 1. The measured inductor performance parameters are shown in Table 1 below.

[0108] Table 1. Performance parameters of the inductors prepared in Examples 1 and 2

[0109]

[0110] The advantages or beneficial effects of adopting the above technical solution are as follows: Compared with the multiple independently installed inductors used in the traditional technical solution, this technical solution realizes the integration of multi-phase inductors, significantly reduces the overall volume of the inductor, and is conducive to the miniaturization of circuits and electronic devices; at the same time, due to the design of the shared magnetic core, this technical solution reduces the total amount of magnetic core used in the inductor, which also effectively reduces the product cost.

[0111] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made using the content of this specification and illustrations should be included within the protection scope of the present invention.

Claims

1. A multiphase integrated inductor, characterized in that, include: The inductor comprises at least two individual inductors, at least one common magnetic core, and at least one outer frame; each individual inductor consists of a central core, a yoke core, a coil, and an inner frame, wherein the permeability of the common core is higher than that of the central core and not lower than that of the yoke core; the individual inductors are tightly bonded to at least one of the common cores.

2. The multiphase integrated inductor according to claim 1, characterized in that, The coil is wound around the central core of the inductor unit, and the upper and lower end faces of the central core are respectively bonded to the middle area of ​​the two yoke iron cores.

3. The multiphase integrated inductor according to claim 1, characterized in that, At least one side of the two yoke cores of the inductor is tightly bonded to the common core; the central cores of different inductor units are parallel to each other.

4. The multiphase integrated inductor according to claim 1, characterized in that, The outer frame is located at both ends of the multiphase integrated inductor; the outer frame is provided with a receiving groove for accommodating the yoke ferromagnetic core and the common magnetic core, and a limiting post for limiting the position of the coil lead-out.

5. The multiphase integrated inductor according to claim 1, characterized in that, The inner frame is located between the yoke ferromagnetic core and the coil of the inductor unit; the inner frame has a through hole for the central column ferromagnetic core to pass through and define its position, and a positioning boss for defining the position of the yoke ferromagnetic core.

6. The multiphase integrated inductor according to claim 1, characterized in that, The central core is one of the following: metal powder core, amorphous magnetic powder core, nanocrystalline magnetic powder core, amorphous ribbon magnetic core, or nanocrystalline ribbon magnetic core.

7. The multiphase integrated inductor according to claim 1, characterized in that, The yoke ferromagnetic core is one of the following: metal powder core, amorphous magnetic powder core, nanocrystalline magnetic powder core, ferrite, amorphous ribbon magnetic core, and nanocrystalline ribbon magnetic core.

8. The multiphase integrated inductor according to claim 1, characterized in that, The common magnetic core is one of the following: metal powder core, amorphous magnetic powder core, nanocrystalline magnetic powder core, ferrite, amorphous ribbon magnetic core, and nanocrystalline ribbon magnetic core.

9. The multiphase integrated inductor according to claim 1, characterized in that, At least one of the yoke core and the common core is an amorphous ribbon core or a nanocrystalline ribbon core.

10. The multiphase integrated inductor according to claim 1, characterized in that, An air gap may be selectively created between the yoke core and the central core.

11. The multiphase integrated inductor according to claim 1, characterized in that, The central core is a complete core or is made up of two or more cores with the same cross-section bonded together. An insulating layer is also attached to the outer ring side of the central core.

12. A method for fabricating a multiphase integrated inductor, characterized in that, include: S1. Component prefabrication: The coil, central core, yoke core, common core, outer frame and inner frame are prefabricated according to the preset dimensions. S2. Inductor unit assembly: Using an assembly fixture, the coil, central core, yoke core and inner frame prefabricated in step S1 are bonded and combined to obtain an inductor unit pre-assembled body. S3. Baking of inductor monomers: Place the assembly fixture and the inductor monomer pre-assembly together in an oven or tunnel oven and bake at a predetermined temperature for a predetermined time. After the adhesive has cured, remove the assembly fixture to obtain the inductor monomer. S4. Semi-finished product preparation: Using the outer frame, a predetermined number of the inductor units are bonded and combined with the common magnetic core to obtain the inductor semi-finished product. S5. Baking and curing: The inductor semi-finished product prepared in step S4 is placed in an oven or tunnel furnace and baked at a predetermined temperature for a predetermined time to cure the adhesive, and finally the multiphase integrated inductor is obtained.

13. The method for fabricating a multiphase integrated inductor according to claim 12, characterized in that, In step S2, the assembly fixture includes: A C-shaped fixed frame is provided with two parallel bottom plates and a top plate, and a baffle that vertically connects the bottom plates and the top plate; A length adjustment device is provided on the top plate of the C-shaped fixed frame.

14. The method for fabricating a multiphase integrated inductor according to claim 12, characterized in that, In steps S2, S3, and S4, performance tests must also be performed on the bonded inductor pre-assembly, the inductor unit, and the inductor semi-finished product.

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