Coupling inductor

Abstract

A coupled inductor includes a core component, at least two first windings, and a second winding. The core component includes a first core and a second core. The first core comprises a first substrate, two first non-wrapping posts and at least two first wrapping posts arranged between the two first non-wrapping posts. The two first non-wrapping posts and the first wrapping post are connected to the first substrate. Each first winding is wound on the corresponding first wrapping post. The second winding covers the at least two first windings. The at least two first windings and the at least two second windings are arranged along a first direction. The first winding direction of the at least two first windings is parallel to the second winding direction of the second winding.

Description

Technical Field

[0001] This invention relates to an electronic component, and more particularly to a coupled inductor used in a power conversion system. Background Technology

[0002] With the rapid development of information technology, the power consumption and current requirements of high-performance computing units such as central processing units (CPUs), graphics processing units (GPUs), and various application-specific integrated circuits (ASICs) are increasing daily. To achieve high-efficiency operation under different load conditions, the core voltage (Vcore) of these computing units needs to be dynamically adjusted in a very short time, and the transient variation in current consumption is also extremely drastic, potentially jumping from low current under low load to high current under high load within microseconds. Traditional voltage regulator modules (VRMs) face significant challenges in coping with such drastic load transients. To maintain core voltage stability, traditional designs often require a large number of decoupling capacitors connected in parallel at the output, which not only occupies valuable printed circuit board (PCB) space but also increases the overall system cost.

[0003] To address this issue, the industry has proposed an advanced architecture called Trans-Inductor Voltage Regulator (TLVR). The TLVR architecture introduces a coupling inductor (or compensating inductor) between the main inductors of a traditional multiphase buck converter. Utilizing the magnetic coupling effect between inductors, it allows all phase inductors to work collaboratively to respond to changes in load current during load transients. Compared to the independent operation of each phase in a traditional VRM, the TLVR architecture significantly improves the system's transient response speed, thereby greatly reducing the need for output capacitors, saving PCB area, and lowering costs.

[0004] However, existing TLVR architecture implementations still have some inherent drawbacks. In a typical TLVR circuit, each phase power stage requires an independent main inductor, and an additional compensation inductor is needed to connect to the outputs of all main inductors. For example, an eight-phase TLVR system requires eight independent main inductors and one compensation inductor. While this approach using multiple discrete inductor components improves electrical performance, it introduces new challenges in component placement and space utilization. These discrete inductors occupy a considerable amount of PCB area, especially in space-constrained areas such as around the CPU or GPU, making this space occupation a major bottleneck in system design. Furthermore, the placement and routing of multiple components increases the complexity of PCB design and may introduce additional parasitic inductance and resistance, thereby affecting the overall efficiency and performance of the system.

[0005] Therefore, the industry has begun to seek solutions that integrate the functions of multiphase main inductors and coupling compensation inductors into a single component. Some existing integrated coil devices may enhance magnetic coupling through overlapping configurations of double-layer conductors. However, these previous structures mainly focus on the coupling between two conductors and do not provide an optimal solution for how to effectively integrate multiple independent power phases into a single magnetic core while simultaneously achieving the high-efficiency transient response required by architectures similar to TLVR. When implementing multiphase integration, these structures may face challenges such as complex magnetic circuit design, difficulty in controlling the symmetry between phases, and difficulty in optimizing DC resistance (DCR).

[0006] Therefore, there is an urgent need for a new type of coupled inductor structure that can not only integrate multiple power phases into a single package to significantly reduce size and save PCB space, but also maintain or even surpass the excellent transient response characteristics of traditional TLVR architectures. Furthermore, this structure should also possess low DC resistance, good heat dissipation performance, and ease of manufacturing to meet the increasingly stringent power solution requirements of next-generation high-performance computing systems. Summary of the Invention

[0007] An embodiment of the present invention provides a coupled inductor comprising a core component, at least two first windings, and a second winding. The core component includes a first core and a second core. The first core includes a first substrate, two first non-wound posts, and at least two first winding posts disposed between the two first non-wound posts. The two first non-wound posts and the first winding posts are connected to the first substrate. Each first winding is wound around a corresponding first winding post. The second winding covers the at least two first windings. The at least two first windings and the second winding are arranged along a first direction. The first winding direction of the at least two first windings and the second winding direction of the second winding are parallel to each other. Attached Figure Description

[0008] Figure 1 This is a three-dimensional schematic diagram of a coupling inductor according to a first embodiment of the present invention.

[0009] Figure 2 This is for Figure 1 The diagram shown is an exploded three-dimensional representation of the coupled inductor.

[0010] Figure 3 This is for Figure 1 The diagram shows a cross-sectional view of the coupled inductor along section 3-3'.

[0011] Figure 4 This is for Figure 2 The diagram shows a three-dimensional representation of the first core.

[0012] Figure 5 This is for Figure 2 The diagram shown is an exploded three-dimensional schematic of the first winding.

[0013] Figure 6 This is for Figure 2 A three-dimensional schematic diagram of the first winding from another perspective.

[0014] Figure 7 This is a schematic diagram showing the different shapes of the inner base plate for the first winding.

[0015] Figure 8 This is a schematic diagram showing the different gap configurations for the coupled inductor.

[0016] Figure 9 This is a schematic diagram of different embodiments of the terminal extension structure for the first winding.

[0017] Figure 10 This is an exploded perspective view of a coupling inductor according to a second embodiment of the present invention.

[0018] Figure 11 This is for Figure 10 The diagram shows a cross-sectional view of the coupled inductor.

[0019] Figure 12 This is for Figure 10 The diagram shows a three-dimensional representation of the first winding.

[0020] Figure 13 This is for Figure 10 A three-dimensional schematic diagram of the winding and terminal configuration of the coupled inductor shown from another perspective.

[0021] Figure 14 This is a three-dimensional schematic diagram of the winding structure according to another embodiment of the present invention.

[0022] The reference numerals in the attached figures are explained as follows:

[0023] 10A, 10B: Coupled inductors

[0024] 20: First Core

[0025] 21: First substrate

[0026] 22: First non-winding post

[0027] 24: First winding post

[0028] 30: Second Core

[0029] 31: Second substrate

[0030] 32: Second non-winding post

[0031] 34: Second winding post

[0032] 50A: First winding

[0033] 50B: First winding

[0034] 50C: First winding

[0035] 51A: First inner side plate

[0036] 51B: Second inner side plate

[0037] 51C: Third inner side plate

[0038] 51D: Fourth inner side plate

[0039] 51E: Fifth inner side plate

[0040] 51F: Sixth inner side panel

[0041] 52A: First Inner Bottom Plate

[0042] 52B: Second Inner Bottom Plate

[0043] 52C: Third Inner Bottom Plate

[0044] 52D: Fourth Inner Plate

[0045] 52E: Fifth Inner Plate

[0046] 52F: Sixth Inner Bottom Plate

[0047] 53A, 53B: Top plate

[0048] 58A: First protrusion

[0049] 58B: Second protrusion

[0050] 61A, 61B: Inner side plate

[0051] 71: Terminal

[0052] 80: Second winding

[0053] 81: Top plate

[0054] 82: First outermost plate

[0055] 83: Second outer lateral plate

[0056] 84: First outer bottom plate

[0057] 85: Second outer bottom plate

[0058] A: First side

[0059] B: Second side

[0060] B1: First outer leg

[0061] B2: Second outer leg

[0062] D1: Thickness of the first substrate

[0063] D2: Width of the first winding post

[0064] Ga: Gap

[0065] H1, H2: Height

[0066] L1: first inner leg

[0067] L2: Second inner leg

[0068] L3: Third inner leg

[0069] L4: The fourth inner leg

[0070] L5: fifth inner leg

[0071] L6: Sixth Inner Leg

[0072] X, Y, Z: Axes

[0073] 3-3': Section Detailed Implementation

[0074] To make the technical content of this invention clearer, preferred embodiments of the invention are described in detail with reference to the accompanying drawings. It must be noted that the embodiments described herein are only a part of the many possible implementations of this invention and are intended for illustrative purposes only, not to limit the scope of protection of this invention. In interpreting the scope of the patent application, the content set forth in the claims should be taken as the basis, and not limited to the description of the embodiments. Furthermore, for clarity and ease of understanding, the dimensions and relative proportions of the elements in the drawings may be simplified or exaggerated, and are not drawn entirely according to actual dimensions. The same or similar element symbols in the drawings represent the same or similar elements.

[0075] Please refer to Figure 1 , Figure 2 and Figure 3 The diagrams illustrate a perspective view, an exploded perspective view, and a cross-sectional view of the coupling inductor 10A according to the first embodiment of the present invention. The coupling inductor 10A of this embodiment is a highly integrated two-phase inductor designed to replace the two discrete main inductors and one compensation inductor in a traditional TLVR architecture. The coupling inductor 10A mainly comprises a core component, two first windings 50A and 50B, and a second winding 80. In circuit applications, these first windings 50A and 50B typically serve as primary windings, while the second winding 80 serves as an auxiliary winding or secondary winding. In three-dimensional spatial coordinates, the directions are defined by three mutually perpendicular axes X, Y, and Z.

[0076] The core components of the coupled inductor 10A include a first core 20 and a second core 30. These two cores 20 and 30 are typically made of ferromagnetic materials with high permeability and low magnetic loss, such as ferrite or alloy powder cores, and can be manufactured through processes such as molding and sintering.

[0077] Please also refer to Figure 2 and Figure 4 The first core 20 has a monolithic structure, comprising a first substrate 21, two first non-wound posts 22 disposed on both sides, and two first wound posts 24 disposed between the two first non-wound posts 22. Both the two first non-wound posts 22 and the two first wound posts 24 extend from the first substrate 21 in the same direction (e.g., the X-axis direction), forming a comb-like structure. Specifically, the first substrate 21 is generally flat, while the first non-wound posts 22 and the first wound posts 24 are columnar structures extending from the surface of the first substrate 21.

[0078] In this embodiment, the second core 30 is shown as a structure symmetrical to the first core 20, and it also includes a second substrate 31, two second non-wound posts 32, and two second wound posts 34. When the coupled inductor 10A is assembled, the first core 20 and the second core 30 are joined face-to-face, such that the first non-wound post 22 is aligned with the second non-wound post 32, and the first wound post 24 is aligned with the second wound post 34, together forming a closed or nearly closed complete magnetic circuit. It is worth noting that in other embodiments not shown, the structure of the second core 30 can be simplified to a flat magnetic core, which is called an EI-type magnetic core, and can also form an effective magnetic circuit, falling within the scope of this invention.

[0079] The two first windings 50A and 50B (main windings) correspond to the two power phases of the power converter. Each first winding 50A and 50B is made of a conductive material, such as highly conductive copper, and can be a flat copper strip or sheet to reduce DC resistance (DCR) and increase current carrying capacity. Figure 2 and Figure 3 As shown, the first winding 50A is wound around one of the first winding posts 24, while the first winding 50B is wound around the other first winding post 24. These two first windings 50A and 50B are arranged side by side along the Z-axis.

[0080] The second winding 80 (secondary winding) acts as a compensating inductor in the TLVR architecture. The second winding 80 is also made of conductive material, and its structure is designed as a large U-shaped or loop conductor, capable of simultaneously covering or enclosing the two first windings 50A and 50B. For example... Figure 3 As shown, the cross-section of the second winding 80 is U-shaped, with its opening facing the substrate of the core component. In terms of spatial arrangement, at least two first windings 50A and 50B and the second winding 80 are stacked along a first direction, namely the Z-axis direction. Specifically, the second winding 80 is located outside the first windings 50A and 50B, while the first windings 50A and 50B are located inside the second winding 80.

[0081] Regarding the definition of the winding direction, such as Figure 3As shown in the cross-section, the current paths (i.e., winding directions) of the first windings 50A and 50B can be considered as forming a loop in the YZ plane. Similarly, the current path of the second winding 80 also forms a loop in the YZ plane. Therefore, the first winding directions of at least two of the first windings 50A and 50B are parallel to the second winding direction of the second winding 80. This parallel winding direction configuration, combined with a shared magnetic circuit, enables strong magnetic coupling between the first and second windings, which is the basis for achieving high-efficiency TLVR transient response. When the current in one of the first windings changes, the resulting change in magnetic flux not only passes through its own core post but also through the space surrounded by the second winding, thereby inducing a voltage in the second winding and further affecting the other first winding, thus achieving the goal of coordinated response across all phases.

[0082] Please refer to Figure 4 The document details the dimensional parameters of the first core 20. In this embodiment, the first substrate 21 has a thickness D1 and a height H1. The height H1 refers to the length along the Y-axis. The first winding post 24 has a width D2 and a height H2. The height H2 refers to the height along the Y-axis. According to a preferred embodiment of the invention, these dimensions are designed to satisfy a specific relationship: the product of the thickness D1 and the height H1 of the first substrate 21 is greater than the product of the width D2 and the height H2 of any of the first winding posts 24 (i.e., H1*D1>H2*D2). This product can be considered as representing the cross-sectional area of ​​that portion in the XY or YZ section. The advantage of this design is that a relatively thick and wide first substrate 21 can provide a more robust mechanical support structure and form a low reluctance magnetic path, which facilitates smooth magnetic flux flow and thus improves the overall performance of the inductor.

[0083] Next, please refer to Figure 3 , Figure 5 and Figure 6 To gain a deeper understanding of the detailed structure of the windings, we will use the first winding 50A as an example. The first winding 50B has a symmetrical or similar structure. The first winding 50A includes a first inner leg L1 and a second inner leg L2. For example... Figure 5As shown in the exploded view, the first inner leg L1 includes a first inner side plate 51A and a first inner bottom plate 52A; the second inner leg L2 includes a second inner side plate 51B and a second inner bottom plate 52B. During assembly, a first winding post 24 is disposed between the first inner leg L1 and the second inner leg L2. The first inner bottom plate 52A extends from the bottom end of the first inner side plate 51A toward the second inner leg L2, while the second inner bottom plate 52B extends from the bottom end of the second inner side plate 51B toward the first inner leg L1. Importantly, the ends of the first inner bottom plate 52A and the second inner bottom plate 52B are spaced apart and do not directly contact each other, forming an opening.

[0084] Similarly, another first winding 50B includes a third inner leg L3 and a fourth inner leg L4. The third inner leg L3 includes a third inner side plate 51C and a third inner bottom plate 52C; the fourth inner leg L4 includes a fourth inner side plate 51D and a fourth inner bottom plate 52D. The third inner bottom plate 52C extends toward the fourth inner leg L4, and the fourth inner bottom plate 52D extends toward the third inner leg L3, and the two are also spaced apart from each other.

[0085] Correspondingly, the structure of the second winding 80 includes a top plate 81, a first outer leg B1, and a second outer leg B2. The first outer leg B1 includes a first outer side plate 82 and a first outer bottom plate 84; the second outer leg B2 includes a second outer side plate 83 and a second outer bottom plate 85. Figure 3 As shown, the first outer plate 82 and the second outer plate 83 are located on the outside of the first windings 50A and 50B, respectively. It is noteworthy that the first outer base plate 84 extends in the opposite direction to the first inner base plate 52A (i.e., outwards), while the second outer base plate 85 extends in the opposite direction to the fourth inner base plate 52D (also outwards). This design, where the inner and outer winding terminals (base plates) extend in opposite directions, significantly increases the physical distance between endpoints at different potentials, effectively improving the creepage distance and thus significantly reducing the risk of electrical short circuits or flashovers in high-voltage or high-pollution environments. More specifically, the positions where the first outer leg B1 (composed of 82 and 84) and the first inner leg L1 (composed of 51A and 52A) of the first winding 50A are folded down to the bottom to form electrodes are precisely offset. Where the conductor does not bend down to form an electrode, the gap is naturally smaller; conversely, where there is a bend to form an electrode, the bending points of the two are staggered in space, thus forming a larger gap, which effectively reduces the risk of short circuit.

[0086] To further improve the integrity and mechanical strength of the winding structure, such as Figure 5As shown, the first winding 50A may further include a top plate 53A. The two sides of the top plate 53A are respectively connected to the top ends of the first inner side plate 51A and the second inner side plate 51B, making the first winding 50A form a nearly closed rectangular loop. Simultaneously, the side of the first inner bottom plate 52A is connected to the bottom end of the first inner side plate 51A, and the side of the second inner bottom plate 52B is connected to the bottom end of the second inner side plate 51B. Similarly, the first winding 50B may also include a top plate 53B.

[0087] Please refer to Figure 7 It is a schematic diagram of different shapes designed for the inner base plate of the first winding, in which Figure 7 The three parts (a) to (c) illustrate three different implementation methods. To optimize electrical performance and reduce short-circuit risk, the shape of the inner base plate (taking the first inner base plate 52A and the second inner base plate 52B as examples) can be designed to be asymmetrical. For example... Figure 7 As shown in part (a), the first inner bottom plate 52A has a first side A (connected to the inner side plate 61A) and a second side B (free end) that is generally parallel to it. In this embodiment, the length of the first side A is greater than the length of the second side B, causing the inner bottom plate to have a trapezoidal or other non-rectangular shape. Similarly, the second inner bottom plate 52B also has a longer first side A (connected to the inner side plate 61B) and a shorter second side B. This design is called a staggered design. In this design, only about half the width of the inner leg (e.g., the first inner leg L1) is folded down to the bottom to form the inner bottom plate (e.g., the first inner bottom plate 52A), while the other half of the width is not. The adjacent inner legs (e.g., the second inner leg L2 and the third inner leg L3) bend downwards to form two inner base plates (e.g., the second inner base plate 52B and the third inner base plate 52C) with their positions just offset, so that the solder joint layout on the PCB is also offset, thereby forming a larger gap at the offset, further reducing the risk of short circuit.

[0088] According to experimental and simulation results of the present invention, the ratio of the length of the second side B of the first inner base plate 52A to the length of its first side A, and the ratio of the length of the second side B of the second inner base plate 52B to the length of its first side A, are preferably between 0.25 and 0.7. This ratio range maximizes the distance between the free ends of the two opposing inner base plates (e.g., 52A and 52B) while ensuring sufficient conductive cross-sectional area to reduce DCR. Furthermore, an optimal balance between insulation performance and manufacturing tolerance can be achieved when the shortest straight-line distance between the first inner base plate 52A and the second inner base plate 52B is maintained between 0.7 mm and 1.4 mm. In a particularly preferred embodiment, this distance is 0.8 mm. Figure 7 Part (b) shows another possible shape, where the inner base plate is rectangular, while Figure 7 Part (c) illustrates another trapezoidal design. The core idea behind these designs is to increase the length of potential short-circuit paths through geometric variations. In actual PCB layouts, when terminals with different potentials are soldered to pads, the molten solder tends to form spheres due to surface tension. If the terminals are too close together, solder bridges can easily form, leading to short circuits. The asymmetrical terminal design of this invention ensures sufficient distance even at the closest points, significantly reducing the probability of such manufacturing defects.

[0089] Please refer to Figure 8 It is a schematic diagram of different gap configurations for the coupled inductor, in which Figure 8 The three sections (a) to (c) illustrate three different air gap configurations. The air gap is a crucial structure in inductor design used to store magnetic energy, prevent core saturation, and precisely adjust the inductance value. Figure 8 In part (b), an air gap is provided only between the central first winding post 24 and the corresponding second winding post 34, while the non-winding posts 22 and 32 on both sides are in direct contact. Figure 8 In part (c), the situation is reversed, with an air gap Ga only between the non-wound posts 22 and 32 on both sides, while the central winding posts 24 and 34 are in direct contact. However, research in this invention has found that the above two non-uniform air gap configurations cause the inductance ratio between the primary and secondary windings to deviate from the ideal range (55% to 85%) required by the TLVR architecture. Specifically, the configuration with only the central post air gap ( Figure 8 Part (b) would result in an excessively high proportion (e.g., a minimum greater than 200%), while only the side column air gap configuration ( Figure 8 Part (c) would result in an excessively low percentage (e.g., a maximum value of less than 35%).

[0090] Therefore, the preferred embodiment of the present invention employs as follows Figure 8 The uniform air gap configuration is shown in section (a). That is, between the first core 20 and the second core 30, a first gap Ga is included between one of the two first unwound posts 22 and the corresponding second unwound post 32, and a second gap is included between at least one of the two first wound posts 24 and the corresponding second wound post 34, wherein the first gap Ga and the second gap have substantially the same thickness. This design of equal air gaps on all magnetic circuit branches ensures a uniform distribution of magnetic flux, allowing the self-inductance and mutual inductance of each winding to reach an ideal balance, thereby precisely controlling the inductance ratio within the target range of 55% to 85%. To further stabilize the air gap thickness and adjust the magnetic properties, a filler material, such as a plastic part, glass beads, or any material with a permeability between 1 Henry per meter and 10 Henry per meter, can be filled into the gap.

[0091] Please refer to Figure 9 This is a schematic diagram of different embodiments of the terminal extension structure of the first winding, wherein... Figure 9 The four parts (a) to (d) illustrate four different extension structures. In traditional designs, the winding terminals are typically formed by bending directly downwards from the body. However, modern PCBs, in pursuit of high-density wiring, often have thinner copper foil layers, resulting in higher resistance values ​​for PCB traces. When large currents flow through these high-resistance paths, significant power losses and voltage drops occur, leading to a deterioration in system-level DCR. To address this issue, this invention proposes designing the terminals of the first winding 50A, namely its inner base plates 52A and 52B, with an outward horizontal extension structure. Figure 9 Four different terminal extension designs for the first winding 50A are shown. In the figure, component symbol 71 represents a terminal on the printed circuit board, which can be a pad or a wire, and its shape is designed to match the extension structure of the inner base plates 52A and 52B. As shown, the extensions of the inner base plates 52A and 52B are not limited to a specific shape and can be rectangular (e.g., ...). Figure 9 (as shown in part (a)), L-shaped (as shown in part (a)) Figure 9 (as shown in part (b)) or other shapes that can increase the welding area (such as...) Figure 9 (As shown in sections (c) and (d)). When these extended inner base plates 52A and 52B are soldered onto the printed circuit board, they can cover the wider or thicker corresponding terminals 71, effectively utilizing the lower resistance paths on the PCB to compensate for the high resistance caused by the thin copper foil of the PCB itself. Experimental data show that with a PCB copper thickness of 1.5 ounces, this extension scheme can improve the system's equivalent DCR by more than 45%, significantly improving the overall power efficiency.

[0092] In addition, to ensure high reliability of operation, all windings, including the first windings 50A and 50B and the second winding 80, may have their conductor surfaces covered with an insulating layer, such as insulating varnish or polymer film, to prevent short circuits between turns inside the winding or between the winding and the core.

[0093] Please refer to Figures 10 to 13 The diagram illustrates a coupled inductor 10B according to a second embodiment of the present invention. This embodiment demonstrates a three-phase coupled inductor, whose basic structure and principle are similar to those of the first embodiment, but which is extended to support more power phases. The coupled inductor 10B mainly comprises a core component (composed of a first core 20 and a second core 30), three first windings 50A, 50B, and 50C (main windings), and a common second winding 80 (auxiliary winding).

[0094] In this embodiment, the first core 20 includes a first substrate 21, two first non-wound posts 22, and three first winding posts 24 disposed therebetween. Correspondingly, three first windings 50A, 50B, and 50C are respectively wound on these three first winding posts 24.

[0095] like Figure 11 and Figure 12 As shown, the structure of these three first windings is similar to that in the first embodiment. In addition to the original first windings 50A and 50B, a third first winding 50C is added, which is disposed between the first windings 50A and 50B. The third first winding 50C also includes a fifth inner leg L5 and a sixth inner leg L6. The fifth inner leg L5 includes a fifth inner side plate 51E and a fifth inner bottom plate 52E; the sixth inner leg L6 includes a sixth inner side plate 51F and a sixth inner bottom plate 52F. Similarly, the fifth inner bottom plate 52E extends toward the sixth inner leg L6, and the sixth inner bottom plate 52F extends toward the fifth inner leg L5, and the two are spaced apart from each other.

[0096] It is particularly noteworthy that, such as Figure 11 and Figure 12 As shown, the two outermost first windings 50A and 50B each have an integral protrusion structure formed on their side plates facing the outside of the coupled inductor 10B. Specifically, the first winding 50A includes a first protrusion 58A that protrudes from the outer surface of the first inner side plate 51A toward the negative Z-axis. Conversely, the first winding 50B includes a second protrusion 58B that protrudes from the outer surface of the fourth inner side plate 51D toward the positive Z-axis. The protrusion directions of these two protrusions 58A and 58B are opposite.

[0097] The protrusions 58A and 58B function as mechanical spacers or positioning structures. During assembly, when the first windings 50A, 50B, and 50C are inserted into the second winding 80, the first protrusion 58A abuts against the inner wall of the first outer plate 82 of the second winding 80, while the second protrusion 58B abuts against the inner wall of the second outer plate 83 of the second winding 80. In this way, a minimum and fixed distance is established and maintained between the main windings (50A, 50B) and the secondary windings (80) along the Z-axis. This preset distance ensures sufficient insulation clearance between them, effectively preventing the risk of electrical short circuits caused by excessive proximity, even under the influence of manufacturing tolerances, vibration, or thermal expansion and contraction, thereby significantly improving the overall reliability of the coupled inductor 10B.

[0098] The structure of the second winding 80 is also expanded accordingly, with an increased width of its top plate 81 to simultaneously cover the three first windings 50A, 50B, and 50C. The structures of its first outer leg B1 and second outer leg B2 are the same as in the first embodiment. Figure 11 As shown, the inner side plates 51A, 51E, 51F, 51C, 51B and 51D of the first windings 50A, 50C and 50B are all housed within the space enclosed by the top plate 81, the first outer side plate 82 and the second outer side plate 83 of the second winding 80.

[0099] Figure 13 The terminal layout of the three-phase coupled inductor 10B is shown. It can be seen that the inner base plates (terminals) 52A to 52F of the three first windings 50A, 50B, and 50C, and the outer base plates (terminals) 84 and 85 of the second winding 80, all employ the aforementioned staggered and asymmetrical design to ensure sufficient insulation distance between terminals at different potentials, preventing short circuits. This embodiment demonstrates the good scalability of the invention's architecture, which can be easily expanded from two-phase to three-phase or even more phases to meet the power phase requirements of different applications, while maintaining a compact structure and superior performance.

[0100] Please refer to Figure 14 The diagram illustrates a perspective view of a winding structure according to another embodiment of the present invention. This winding structure is also used in a three-phase coupled inductor and includes three first windings 50A, 50B, and 50C, and one second winding 80. This embodiment is similar to... Figures 11 to 13 The difference between the embodiments lies in that this embodiment further incorporates the two outer base plates 84 and 85 of the second winding 80 into the staggered design of the original inner base plates 52A to 52F, in order to maximize the electrical spacing between the various base plates and thus reduce the risk of short circuits. Specifically, in the embodiments of Figures 11 to 13, the width of the outer base plates 84 and 85 along the X-axis is equal to the width of the first outer plate 82 and the second outer plate 83 along the X-axis. In contrast, Figure 14 In this embodiment, the widths of the outer base plates 84 and 85 along the X-axis are less than half the widths of the first outer plate 82 and the second outer plate 83 along the X-axis. For example... Figure 14 As shown, the width of the first outer plate 82 and the second outer plate 83 along the X-axis is half. Figure 14As shown, the portions of the outer base plate 84 and the inner base plate 52A projected onto the XZ plane along a direction parallel to the Y-axis do not overlap, and the portions of the outer base plate 85 and the inner base plate 52D projected onto the XZ plane along a direction parallel to the Y-axis also do not overlap. Furthermore, the base plates between adjacent legs are intentionally offset. For example, the outer base plate 84 and inner base plate 52A of adjacent first outer leg B1 and first inner leg L1 are offset; the outer base plate 85 and inner base plate 52D of adjacent second outer leg B2 and fourth inner leg L4 are offset. The arrangement of the inner base plates 52A to 52F of the three first windings 50A, 50B, and 50C is similar to... Figures 11 to 13 The settings are the same as in the embodiments, so they will not be described again. Additionally, by Figure 14 It can be seen that the outer bottom plate 84, inner bottom plate 52B, inner bottom plate 52F and inner bottom plate 52D extend in the negative Z-axis direction, while the outer bottom plate 85, inner bottom plate 52C, inner bottom plate 52E and inner bottom plate 52A extend in the Z-axis direction.

[0101] In summary, the coupled inductor disclosed in this invention, through its innovative multiphase integrated core structure, uniform air gap configuration, and sophisticated winding and terminal geometry design, successfully solves the problems of excessive space occupation in discrete TLVR solutions and the design difficulties of integrated solutions in previous technologies. This invention not only significantly reduces component size and improves PCB space utilization, but also achieves excellent transient response performance, lower DC resistance, and higher system reliability through optimized magnetic and circuit design. It perfectly meets the stringent requirements of modern high-performance computing systems for power supplies and has extremely high industrial application value.

[0102] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made in accordance with the claims of the present invention should be included within the scope of the present invention.

Claims

1. A coupled inductor comprising: A core component, which includes: A first core includes a first substrate, two first non-wound posts, and at least two first wound posts disposed between the two first non-wound posts, wherein the two first non-wound posts and the first wound posts are connected to the first substrate; and The second core; At least two first windings, each of which is wound on a corresponding first winding post; as well as A second winding covers the at least two first windings; Wherein, the at least two first windings and the second winding are arranged along a first direction; and Wherein, the first winding direction of the at least two first windings and the second winding direction of the second winding are parallel to each other.

2. The coupled inductor of claim 1, wherein the product of a thickness and a height of the first substrate is greater than the product of a width and a height of any of the first winding posts.

3. The coupled inductor as claimed in claim 1, wherein one of the at least two first windings includes a first inner leg and a second inner leg, and the other of the at least two first windings includes a third inner leg and a fourth inner leg. The first inner leg includes a first inner side plate and a first inner bottom plate, and the second inner leg includes a second inner side plate and a second inner bottom plate. The first inner bottom plate extends toward the second inner leg, and the second inner bottom plate extends toward the first inner leg. The first inner bottom plate and the second inner bottom plate are spaced apart from each other. The third inner leg includes a third inner side plate and a third inner bottom plate, and the fourth inner leg includes a fourth inner side plate and a fourth inner bottom plate. The third inner bottom plate extends toward the fourth inner leg, and the fourth inner bottom plate extends toward the third inner leg, with the third inner bottom plate and the fourth inner bottom plate spaced apart from each other. The second winding includes a top plate, a first outer leg, and a second outer leg. The first outer leg includes a first outer side plate and a first outer bottom plate. The second outer leg includes a second outer side plate and a second outer bottom plate. The first outer bottom plate extends in the opposite direction to the first inner bottom plate, and the second outer bottom plate extends in the opposite direction to the fourth inner bottom plate.

4. The coupled inductor as claimed in claim 3, wherein one first winding post is disposed between the first inner leg and the second inner leg, and the other first winding post is disposed between the third inner leg and the fourth inner leg.

5. The coupled inductor of claim 3, wherein a width of the first outer base plate is smaller than a width of the first outer side plate, and the first outer base plate and the first inner base plate are offset from each other; and The width of the second outer bottom plate is smaller than the width of the second outer side plate, and the second outer bottom plate and the fourth inner bottom plate are offset from each other.

6. The coupled inductor of claim 3, further comprising a third first winding disposed between one of the at least two first windings and the other of the at least two first windings, wherein the third first winding comprises a fifth inner leg and a sixth inner leg, the fifth inner leg comprises a fifth inner side plate and a fifth inner bottom plate, the sixth inner leg comprises a sixth inner side plate and a sixth inner bottom plate, the fifth inner bottom plate extends toward the sixth inner leg, the sixth inner bottom plate extends toward the fifth inner leg, and the fifth inner bottom plate and the sixth inner bottom plate are spaced apart from each other.

7. The coupled inductor of claim 3, wherein one of the at least two first windings further includes a first protrusion that protrudes from an outer surface of the first inner plate and abuts against the first outer plate of the second winding; and One of the at least two first windings further includes a second protrusion that protrudes from an outer surface of the fourth inner plate and abuts against the second outer plate of the second winding.

8. The coupled inductor as claimed in claim 3, wherein the first inner base plate and the second inner base plate each have a first side and a second side parallel to the first side, and the length of each first side is greater than the length of the corresponding second side.

9. The coupling inductor of claim 8, wherein the ratio of the length of the second side of the first inner base plate to the length of the first side of the first inner base plate is between 0.25 and 0.7, and the ratio of the length of the second side of the second inner base plate to the length of the first side of the second inner base plate is between 0.25 and 0.

7.

10. The coupled inductor of claim 9, wherein the distance between the first inner base plate and the second inner base plate is between 0.7 mm and 1.4 mm.

11. The coupled inductor of claim 10, wherein the distance between the first inner base plate and the second inner base plate is 0.8 mm.

12. The coupled inductor of claim 7, wherein, in a top view of the coupled inductor, the first inner base plate and the second inner base plate are disposed between the first inner side plate and the second inner side plate.

13. The coupled inductor of claim 1, wherein one of the at least two first windings includes a top plate, a first inner leg and a second inner leg, wherein two sides of the top plate are respectively connected to the first inner leg and the second inner leg.

14. The coupled inductor of claim 1, wherein the second core comprises a second substrate, two second non-wound posts, and at least two second wound posts disposed between the two second non-wound posts, wherein the two second non-wound posts and the second wound posts are connected to the second substrate, and each of the first windings is wound on a second wound post corresponding to one of the first wound posts.

15. The coupled inductor of claim 1, wherein the second core comprises a second substrate, two second unwound posts, and at least two second wound posts disposed between the two second unwound posts, wherein the two second unwound posts and the second wound posts are connected to the second substrate, and one of the two first unwound posts and a second unwound post corresponding to one of the two first unwound posts includes a first gap, and one of the at least two first wound posts and a second wound post corresponding to one of the first wound posts includes a second gap, wherein the first gap and the second gap have the same thickness.

16. The coupled inductor of claim 15, further comprising a filler material filling the first gap and the second gap, wherein the permeability of the filler material is between 1 Henry per meter and 10 Henry per meter.

17. The coupled inductor of claim 1, wherein the surfaces of the at least two first windings and the second winding are respectively covered with an insulating layer.

18. The coupled inductor of claim 1, wherein the inductance ratio of any of the first windings to the second winding is between 55% and 85%.

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