Coupling inductor
By designing interleaved winding groups and insulating oxide thin film groups in the coupled inductor, the problem of insufficient coupling coefficient was solved, and more efficient voltage conversion performance was achieved.
Patent Information
- Application Number
- CN202411099360.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-12
- Publication Date
- 2026-02-13
AI Technical Summary
The existing coupled inductor has a small overlap area between the two windings, resulting in a poor coupling coefficient, which cannot meet the requirements for high-efficiency voltage conversion.
The first and second winding groups are designed to overlap and intersect each other in the height direction of the magnetic structure, and an insulating oxide thin film group is set in between for electrical isolation. The width and thickness of the film are adjusted to adjust the saturation current and inductance of the coupled inductor.
By employing an interleaved design and adjusting the insulating oxide film, the coupling coefficient and inductance of the coupled inductor are significantly improved, adapting to different application requirements.
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Figure CN121528706A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to a passive component, and more particularly to a coupled inductor. BACKGROUND
[0002] A coupled inductor connects two coils or inductors by electromagnetic induction. A coupled inductor is designed by coupling two coils, which can reduce the ripple current and thus improve the conversion efficiency. Therefore, the coupled inductor is suitable for voltage converters.
[0003] The coupled inductor on the market usually stacks two winding lines up and down. However, under such a design, the overlapping area of the two winding lines is small, resulting in poor coupling coefficient. SUMMARY
[0004] Therefore, an object of the present application is to provide a coupled inductor, wherein a first winding set and a second winding set correspondingly overlap and interleave in the height direction of a magnetic structure. Such interleaving design can greatly increase the overlapping area between the first winding set and the second winding set, and thus improve the coupling coefficient of the coupled inductor.
[0005] Another object of the present application is to provide a coupled inductor, wherein an insulating oxide film set is arranged in the gap between the first winding set and the second winding set to electrically isolate the first winding set and the second winding set. By adjusting the width and thickness of the film of the insulating oxide film set, the saturation current and inductance of the coupled inductor can be adjusted to facilitate various applications.
[0006] According to the above-mentioned objects of the present application, a coupled inductor is provided, which comprises a magnetic structure, a first winding set, a second winding set, and an insulating oxide film set. The magnetic structure comprises a magnetic core. The first winding set is arranged in the magnetic structure and wound outside the magnetic core. The second winding set is arranged in the magnetic structure and wound outside the magnetic core. The first winding set and the second winding set correspondingly overlap and interleave in the height direction of the magnetic structure. The insulating oxide film set is arranged between the first winding set and the second winding set to electrically isolate the first winding set and the second winding set.
[0007] According to an embodiment of the present application, the first winding set comprises a first winding layer and a second winding layer that are connected to each other, and the second winding set comprises a third winding layer and a fourth winding layer that are connected to each other. The third winding layer is arranged between the first winding layer and the second winding layer in the height direction of the magnetic structure, and the second winding layer is arranged between the third winding layer and the fourth winding layer in the height direction of the magnetic structure.
[0008] According to an embodiment of the present application, the insulating oxide film set includes a first insulating oxide film sandwiched between the first winding layer and the third winding layer, a second insulating oxide film sandwiched between the third winding layer and the second winding layer, and a third insulating oxide film sandwiched between the second winding layer and the fourth winding layer.
[0009] According to an embodiment of the present application, the width of the first insulating oxide film is equal to the width of the first winding layer and the width of the third winding layer, the width of the second insulating oxide film is equal to the width of the third winding layer and the width of the second winding layer, and the width of the third insulating oxide film is equal to the width of the second winding layer and the width of the fourth winding layer.
[0010] According to an embodiment of the present application, the width of the first insulating oxide film is greater than the width of the first winding layer and the width of the third winding layer, the width of the second insulating oxide film is greater than the width of the third winding layer and the width of the second winding layer, and the width of the third insulating oxide film is greater than the width of the second winding layer and the width of the fourth winding layer.
[0011] According to an embodiment of the present application, the first insulating oxide film, the second insulating oxide film, and the third insulating oxide film completely penetrate or partially penetrate the magnetic core.
[0012] According to an embodiment of the present application, the first insulating oxide film, the second insulating oxide film, and the third insulating oxide film completely penetrate or partially penetrate the magnetic structure.
[0013] According to an embodiment of the present application, the first winding layer and the second winding layer are joined by a first joining layer extending along the height direction of the magnetic structure.
[0014] According to an embodiment of the present application, the third winding layer and the fourth winding layer are joined by a second joining layer extending along the height direction of the magnetic structure.
[0015] According to an embodiment of the present application, the first joining layer is adjacent to and opposite to the second joining layer. Between the first joining layer and the second joining layer, the first winding layer and the fourth winding layer are opposite to each other, and the magnetic structure is interposed between the first winding layer and the fourth winding layer opposite to each other. BRIEF DESCRIPTION OF DRAWINGS
[0016] A better understanding of the present application can be obtained from the following detailed description in conjunction with the following drawings, in which:
[0017] Figure 1FIG. 1 is a perspective view illustrating a coupled inductor according to an embodiment of the present application.
[0018] Figure 2 FIG. 2 is a top view illustrating a coupled inductor according to an embodiment of the present application.
[0019] Figure 3 FIG. 3 is a side view illustrating a coupled inductor according to an embodiment of the present application.
[0020] Figure 4 FIG. 4 is a perspective view illustrating a first winding set of a coupled inductor according to an embodiment of the present application.
[0021] Figure 5 FIG. 5 is a perspective view illustrating a second winding set of a coupled inductor according to an embodiment of the present application.
[0022] Figure 6 FIG. 6 is a perspective view illustrating a combination of the first winding set and the second winding set of a coupled inductor according to an embodiment of the present application.
[0023] Figure 7 FIG. 7 is a perspective view illustrating a combination of the first winding set, the second winding set, and the insulating oxide film set of a coupled inductor according to an embodiment of the present application. DETAILED DESCRIPTION
[0024] Embodiments of the present application are discussed in detail below. It should be appreciated, however, that the embodiments provide many applicable concepts that can be embodied in a wide variety of specific contexts. The embodiments discussed and disclosed are merely for illustrative purposes and are not intended to limit the scope of the present application. All embodiments of the present application disclose various features that can be implemented alone or in combination with others.
[0025] In addition, the terms "first", "second", etc. used herein are not intended to refer to order or sequence, but are merely used to distinguish one element from another. Accordingly, a first element discussed below could be termed a second element without departing from the teachings of the present application.
[0026] Spatially relative terms, such as "beneath", "below", "lower", "above", "upper" and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the figures. For example, if a device described is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0027] Reference is made to Figures 1 to 3 FIGS. 1, 2, and 3 are a perspective view, a top view, and a side view, respectively, illustrating a coupled inductor 100 according to an embodiment of the present application. Figure 2With Figure 3 The first winding set 300 and the second winding set 400 are indicated with different hatching to clearly show the first winding set 300 and the second winding set 400. The coupled inductor 100 has a high coupling coefficient and can be applied in a multi-phase switching power converter or a flyback inductor regulator, for example. The coupled inductor 100 can mainly include the magnetic structure 200, the first winding set 300, the second winding set 400, and the insulating oxide film set 500.
[0028] In Figure 1 In the embodiment shown, the magnetic structure 200 is a rectangular body structure having an upper surface 202 and a lower surface 204 opposite to each other, and four side surfaces 206, 208, 210, and 212 connecting the upper surface 202 and the lower surface 204. The upper surface 202 and the lower surface 204 are opposite to each other in a height direction HD of the magnetic structure 200. The type of the magnetic structure 200 can be designed according to product requirements, and the present application is not limited thereto. For example, the magnetic structure 200 can be a cylindrical structure, an ellipsoidal structure, a polygonal column structure other than a quadrilateral, etc. As shown in Figure 2 The magnetic structure 200 includes a magnetic core 220 located in a middle region of the magnetic structure 200.
[0029] The magnetic structure 200 can be formed by a lamination method. As shown in Figure 1 With Figure 3 In some embodiments, the magnetic structure 200 includes a first portion 230, a second portion 240, and a third portion 250 stacked in sequence. The materials or particle sizes of the first portion 230, the second portion 240, and the third portion 250 can be the same as or different from each other. In this way, the magnetic permeabilities of the first portion 230, the second portion 240, and the third portion 250 can be the same as or different from each other. The material or particle size of the first portion 230 can be the same as that of the third portion 250 but different from that of the second portion 240. In this way, the magnetic permeability of the first portion 230 can be the same as that of the third portion 250 but different from that of the second portion 240.
[0030] Please refer to Figure 4 which is a perspective view showing the first winding set 300 of a coupled inductor 100 according to an embodiment of the present application. The first winding set 300 is disposed in the magnetic structure 200 and surrounds the magnetic core 220. Specifically, the first winding set 300 is embedded in the interior of the magnetic structure 200 and located between the upper surface 202 and the lower surface 204. The first winding set 300 is located in the second portion 240. For example, the first winding set 300 can be located in the middle region in the height direction HD of the magnetic structure 200.
[0031] In some embodiments, asFigure 3 and Figure 4 As shown, the first winding assembly 300 includes a first winding layer 310 and a second winding layer 320. In the height direction HD of the magnetic structure 200, the first winding layer 310 is located above the second winding layer 320. The first winding layer 310 and the second winding layer 320 are respectively wound around the magnetic core 220 and joined together to form a first winding turn. For example, the first winding layer 310 and the second winding layer 320 may each be wound around the magnetic core 220 approximately one turn, such that the first winding turn is wound around the magnetic core 220 approximately two turns. In some embodiments, the first winding assembly 300 further includes a first bonding layer 330. The first bonding layer 330 extends along the height direction HD of the magnetic structure 200 between the first winding layer 310 and the second winding layer 320, and the opposite ends of the first bonding layer 330 are respectively bonded to the first winding layer 310 and the second winding layer 320 to connect the first winding layer 310 and the second winding layer 320. The windings 312 of the first winding layer 310 and 322 of the second winding layer 320 may have the same shape and size, and most of the windings 312 and 322 may overlap in the height direction HD of the magnetic structure 200. In some embodiments, the windings 312 and 322 have the same width. The materials of the windings 312 and 322 may be, for example, metallic conductive materials.
[0032] Please refer to the following at the same time Figure 5 This is a perspective view illustrating a second winding group 400 of a coupled inductor 100 according to an embodiment of the present invention. The second winding group 400 is disposed inside the magnetic structure 200, located between the upper surface 202 and the lower surface 204, and wraps around the magnetic core 220. The second winding group 400 is located in the second portion 240. The second winding group 400 may also be located in the middle region in the height direction HD of the magnetic structure 200.
[0033] In some embodiments, such as Figure 3 and Figure 5As shown, the second winding set 400 includes a third winding layer 410 and a fourth winding layer 420. In the height direction HD of the magnetic structure 200, the third winding layer 410 is located above the fourth winding layer 420. The third winding layer 410 and the fourth winding layer 420 are respectively wound around the magnetic core 220 and engaged with each other to form a second winding turn, which corresponds to the first winding turn. For example, the third winding layer 410 and the fourth winding layer 420 can each be wound around the magnetic core 220 nearly one turn, such that the second winding turn is about two turns around the magnetic core 220. In some embodiments, the second winding set 400 further includes a second engagement layer 430. The second engagement layer 430 extends in the magnetic structure 200 along the height direction HD of the magnetic structure 200, and opposite ends of the second engagement layer 430 are respectively engaged with the third winding layer 410 and the fourth winding layer 420 to connect the third winding layer 410 and the fourth winding layer 420. The winding 412 of the third winding layer 410 and the winding 422 of the fourth winding layer 420 can have the same shape, and the width and thickness of the windings 412 and 422 can be the same size. Most of the windings 412 and 422 can overlap in the height direction HD of the magnetic structure 200. The materials of the windings 412 and 422 can be, for example, metal conductive materials.
[0034] Please refer to Figure 1 , Figure 3 , and Figure 6 , wherein Figure 6 is a perspective view illustrating a combination of the first winding set 300 and the second winding set 400 of the coupled inductor 100 according to an embodiment of the present application. The first winding set 300 and the second winding set 400 correspondingly overlap and are staggered with each other in the height direction HD of the magnetic structure 200. Specifically, in the height direction HD of the magnetic structure 200, the third winding layer 410 of the second winding set 400 is located between the first winding layer 310 and the second winding layer 320 of the first winding set 300, and the second winding layer 320 is located between the third winding layer 410 and the fourth winding layer 420. That is, in the order of the first winding layer 310, the third winding layer 410, the second winding layer 320, and the fourth winding layer 420 along the height direction HD of the magnetic structure 200.
[0035] Since the first winding layer 310 and the second winding layer 320 of the first winding set 300, and the third winding layer 410 and the fourth winding layer 420 of the second winding set 400 correspondingly overlap and are staggered with each other in the height direction HD of the magnetic structure 200. By this design, the overlapping area between the first winding set 300 and the second winding set 400 can be greatly increased, and the coupling coefficient of the coupled inductor 100 can be improved.
[0036] Please refer to Figure 2 , Figure 3 , and Figure 7wherein Figure 7 Fig. 4 is a perspective view illustrating a first winding set 300, a second winding set 400, and an insulating oxide film set 500 of a coupled inductor 100 according to an embodiment of the present application. The insulating oxide film set 500 is disposed in the magnetic structure 200 and between the first winding set 300 and the second winding set 400 to electrically separate the first winding set 300 and the second winding set 400 and prevent the first winding set 300 and the second winding set 400 from shorting. Thus, the insulating oxide film set 500 is located in the second portion 240. The insulating oxide film set 500 can be made of a high-temperature and high-pressure resistant material such as glass or ceramic.
[0037] In Figure 3 and Figure 7 the illustrated embodiment, the insulating oxide film set 500 includes a first insulating oxide film 510, a second insulating oxide film 520, and a third insulating oxide film 530. The first insulating oxide film 510, the second insulating oxide film 520, and the third insulating oxide film 530 are arranged from top to bottom in the height direction HD of the magnetic structure 200. As shown in Figure 3 the first insulating oxide film 510 is disposed between adjacent first winding layers 310 and third winding layers 410 to separate the first winding layers 310 and the third winding layers 410. The second insulating oxide film 520 is disposed between adjacent third winding layers 410 and second winding layers 320 to separate the third winding layers 410 and the second winding layers 320. The third insulating oxide film 530 is disposed between adjacent second winding layers 320 and fourth winding layers 420 to separate the second winding layers 320 and the fourth winding layers 420.
[0038] In some embodiments, as shown in Figure 7 the first insulating oxide film 510, the second insulating oxide film 520, and the third insulating oxide film 530 are the same as the first winding set 300 and the second winding set 400 and have an open or closed ring structure surrounding the magnetic core 220. In such embodiments, the shapes of the first insulating oxide film 510, the second insulating oxide film 520, and the third insulating oxide film 530 can be the same as those of the corresponding winding layers to be separated, but the sizes of the first insulating oxide film 510, the second insulating oxide film 520, and the third insulating oxide film 530 should be large enough to cover the corresponding winding layers to be separated to prevent shorting of adjacent winding layers.
[0039] In some embodiments, as shown in Figure 2As shown, the width of the first insulating oxide film 510 is greater than the width of the first winding layer 310 and the third winding layer 410, the width of the second insulating oxide film 520 is greater than the width of the third winding layer 410 and the second winding layer 320, and the width of the third insulating oxide film 530 is greater than the width of the second winding layer 320 and the fourth winding layer 420. In other embodiments, the width of the first insulating oxide film 510 is equal to the width of the first winding layer 310 and the third winding layer 410, the width of the second insulating oxide film 520 is equal to the width of the third winding layer 410 and the second winding layer 320, and the width of the third insulating oxide film 530 is equal to the width of the second winding layer 320 and the fourth winding layer 420. That is, each film of the insulating oxide film set 500, each winding layer of the first winding set 300, and each winding layer of the second winding set 400 are of equal width and substantially aligned.
[0040] In yet other embodiments, the first insulating oxide film 510, the second insulating oxide film 520, and the third insulating oxide film 530 are in a plate-like structure, not only located between adjacent winding layers, but also completely or partially penetrating the magnetic core 220. In such embodiments, the first insulating oxide film 510, the second insulating oxide film 520, and the third insulating oxide film 530 can not only penetrate the magnetic core 220, but also completely penetrate the magnetic structure 200, and be exposed in the side surfaces 206, 208, 210, and 212 of the magnetic structure 200.
[0041] Please refer to Figure 1 and Figure 7 The first bonding layer 330 of the first winding set 300 is adjacent to the second bonding layer 430 of the second winding set 400, and is opposite to the second bonding layer 430. In some embodiments, between the first bonding layer 330 and the second bonding layer 430, the first winding layer 310 and the fourth winding layer 420 are opposite to each other, and the magnetic structure 200 is located between the first winding layer 310 and the fourth winding layer 420. In other embodiments, between the first bonding layer 330 and the second bonding layer 430, in addition to the magnetic structure 200, the insulating oxide film set 500 can also be located between the first winding layer 310 and the fourth winding layer 420.
[0042] By controlling the width and thickness of the insulating oxide film set 500, the saturation current and inductance of the coupled inductor 100 can be adjusted. The width of the insulating oxide film set 500 is increased, the width of the insulating oxide film set 500 is increased, but the area of the magnetic material is reduced, resulting in a decrease in inductance. Therefore, according to the application requirements of the product, the width of the insulating oxide film set 500 can be adjusted, so that the coupled inductor 100 can be applied in higher circuit design.
[0043] The coupling inductor 100 can be manufactured by sequentially printing the insulating oxide film and the winding layer, printing the magnetic material in the middle region and the periphery of the stacked layer of the insulating oxide film and the winding layer, and stacking the printed stacked layer to form a laminated structure. After the laminated structure is cut, sintered, and electrode-plated, the manufacturing of the coupling inductor 100 is basically completed.
[0044] As can be seen from the above embodiments, an advantage of the present application is that the first winding group and the second winding group of the coupling inductor correspond to and overlap each other in the height direction of the magnetic structure. Such an interlaced design can greatly increase the overlapping area between the first winding group and the second winding group, and can improve the coupling coefficient of the coupling inductor.
[0045] Another advantage of the present application is that the width and width of the insulating oxide film group arranged between the first winding group and the second winding group can be adjusted to adjust the saturation current and inductance of the coupling inductor, which is beneficial for various application requirements.
[0046] Although the present application has been disclosed as above by way of examples, it is not intended to limit the present application, and any person skilled in the art can make various modifications and decorations without departing from the spirit and scope of the present application. Therefore, the protection scope of the present application shall be subject to the appended claims.
[0047]
Symbol Description
[0048] 100: coupling inductor
[0049] 200: magnetic structure
[0050] 202: upper surface
[0051] 204: lower surface
[0052] 206: side surface
[0053] 208: side surface
[0054] 210: side surface
[0055] 212: side surface
[0056] 220: magnetic core
[0057] 230: first part
[0058] 240: second part
[0059] 250: third part
[0060] 300: first winding group
[0061] 310: first winding layer
[0062] 312: wire winding
[0063] 320: second wire winding layer
[0064] 322: wire winding
[0065] 330: first bonding layer
[0066] 400: second wire winding group
[0067] 410: third wire winding layer
[0068] 412: wire winding
[0069] 420: fourth wire winding layer
[0070] 422: wire winding
[0071] 430: second bonding layer
[0072] 500: insulating oxide film group
[0073] 510: first insulating oxide film
[0074] 520: second insulating oxide film
[0075] 530: third insulating oxide film
[0076] HD: height direction
Claims
1. A coupled inductor, characterized in that, The coupling inductor includes: Magnetic structure, including a magnetic core; The first winding group is located in the magnetic structure and wound around the magnetic core; A second winding group is disposed within the magnetic structure and wound around the magnetic core, wherein the first winding group and the second winding group overlap and intersect each other in the height direction of the magnetic structure; and An insulating oxide film assembly is provided between the first winding assembly and the second winding assembly to electrically isolate the first winding assembly and the second winding assembly.
2. The coupled inductor according to claim 1, characterized in that, The first winding assembly includes a first winding layer and a second winding layer that are joined together, and the second winding assembly includes a third winding layer and a fourth winding layer that are joined together. The third winding layer is located between the first winding layer and the second winding layer in the height direction of the magnetic structure, and the second winding layer is located between the third winding layer and the fourth winding layer in the height direction of the magnetic structure.
3. The coupled inductor according to claim 2, characterized in that, The insulating oxide thin film assembly comprises: A first insulating oxide film is sandwiched between the first winding layer and the third winding layer; A second insulating oxide film is sandwiched between the third winding layer and the second winding layer; as well as A third insulating oxide film is sandwiched between the second winding layer and the fourth winding layer.
4. The coupled inductor according to claim 3, characterized in that, The width of the first insulating oxide film is equal to the width of the first winding layer and the width of the third winding layer, the width of the second insulating oxide film is equal to the width of the third winding layer and the width of the second winding layer, and the width of the third insulating oxide film is equal to the width of the second winding layer and the width of the fourth winding layer.
5. The coupled inductor according to claim 3, characterized in that, The width of the first insulating oxide film is greater than the width of the first winding layer and the width of the third winding layer, the width of the second insulating oxide film is greater than the width of the third winding layer and the width of the second winding layer, and the width of the third insulating oxide film is greater than the width of the second winding layer and the width of the fourth winding layer.
6. The coupled inductor according to claim 3, characterized in that, The first insulating oxide film, the second insulating oxide film, and the third insulating oxide film completely or partially penetrate the magnetic core.
7. The coupled inductor according to claim 3, characterized in that, The first insulating oxide film, the second insulating oxide film, and the third insulating oxide film completely penetrate the magnetic structure.
8. The coupled inductor according to claim 3, characterized in that, The first winding layer and the second winding layer are joined by a first bonding layer extending along the height direction of the magnetic structure.
9. The coupled inductor according to claim 8, characterized in that, The third winding layer and the fourth winding layer are joined by a second bonding layer extending along the height direction of the magnetic structure.
10. The coupled inductor according to claim 9, characterized in that, The first bonding layer is adjacent to and opposite to the second bonding layer, wherein between the first bonding layer and the second bonding layer, the first winding layer and the fourth winding layer are opposite to each other, and the magnetic structure is located between the opposing first winding layer and the fourth winding layer.