TLVR coupling inductor

Abstract

The utility model discloses a TLVR coupling inductor which is formed by assembling a primary coil, a secondary coil and a magnetic core, the primary coil acts with the magnetic core in a power-on state to generate a first inductor, and the secondary coil acts with the magnetic core in a power-on state to generate a second inductor coupled with the first inductor. The pre-formed primary coil and the pre-formed secondary coil are connected into an internally and externally nested coil module through an insulating interlayer, and two stages of coils of the coil module are separated by the insulating interlayer; the magnetic core wraps the coil module, and all pins formed by bending the two-stage coils are exposed on the same side. According to the TLVR coupling inductor, the structure is optimized, the primary coil and the secondary coil which are not coated in an insulating mode are connected through the insulating interlayer to form the isolated coil module, on one hand, the withstand voltage between the two coils is greatly improved and can reach 200 V or above, meanwhile, assembly of the coil module and the magnetic core is simplified, the TLVR coupling inductor is suitable for being connected into an automatic production line, and the production efficiency is improved. Therefore, the production efficiency is effectively improved.

Description

Technical Field

[0001] The utility model relates to an inductor device, in particular to an improved inductor structure for improving the insulation performance between two-level coils, and belongs to the technical field of basic electronic components. Background Art

[0002] Inductors are the most commonly used components in electronic devices and are widely used in various circuits to achieve the functions of filtering, energy storage, matching, and resonance. As electronic products become increasingly miniaturized and portable, and components are assembled with high density, inductor components have developed rapidly; and in consideration of electromagnetic compatibility, the ability of electronic products to resist electromagnetic interference has become a basic design requirement, which has increased the demand and application of inductors.

[0003] The TLVR (Trans-Inductor Voltage Regulator) architecture is a newly developed VR (Voltage Regulator) power supply architecture in recent years. The biggest difference between it and the traditional DC to DCBuck (DC-DC buck) and DC (DC) architectures is that the traditional single-winding ordinary inductor is replaced with a transformer-like TLVR inductor with double windings. The ordinary inductor has only one set of windings and two pins, while the TLVR inductor has two sets of mutually coupled windings and four pins. There is a huge difference in the structural form of the two.

[0004] When designing the structure of TLVR inductors, the coupling efficiency between the two coils is the main goal of the industry. In addition to the selection of core materials, general prefabrication and assembly, the mutual insulation performance between the two coils is a necessary guarantee for the coupling efficiency. Summary of the invention

[0005] In view of the above-mentioned defects in the prior art, the purpose of the utility model is to provide a TLVR coupled inductor, which improves the insulation performance between the primary and secondary coils by optimizing the internal structure of the device.

[0006] The technical solution for achieving the above-mentioned purpose of the utility model is: a TLVR coupled inductor, which is composed of a primary coil, a secondary coil and a magnetic core, and the primary coil reacts with the magnetic core to generate a first inductance when it is energized, and the secondary coil reacts with the magnetic core to generate a second inductance coupled with the first inductance when it is energized, and is characterized in that: the preformed primary coil and the secondary coil are connected to form an inner and outer nested coil module through an insulating interlayer, and the two-pole coils of the coil module are separated by an insulating interlayer; the magnetic core wraps the coil module and exposes all the pins formed by bending the two-pole coils on the same side.

[0007] Furthermore, the primary coil and the secondary coil are both bare benign conductors.

[0008] Furthermore, the insulating interlayer is a plastic open loop that is injection-molded between the two-stage coils, or an epoxy colloid that is filled, bonded and cured between the two-stage coils.

[0009] Furthermore, the two ends of the primary coil are bent outward to form a first pin and a fourth pin, and the two ends of the secondary coil are bent inward to form a second pin and a third pin that are separated from each other, and the first pin and the second pin are separated by an end edge on one side of the insulating interlayer, and the third pin and the fourth pin are separated by an end edge on the other side of the insulating interlayer.

[0010] Furthermore, the magnetic core is composed of two independently formed magnetic shells, and in the spliced ​​assembly state, an installation groove suitable for positioning and loading the coil module is formed inside the magnetic core, the outer wall spacing of the installation groove is adapted to the primary coil being compatible therein, and the inner wall spacing of the installation groove is adapted to the secondary coil being sleeved thereon.

[0011] Furthermore, the magnetic core is composed of a U-shaped magnetic shell and a T-shaped magnetic shell, or is composed of two E-shaped magnetic shells with the same appearance.

[0012] Furthermore, the magnetic core is a molded body made of manganese-zinc ferrite powder or alloy iron powder.

[0013] Compared with the prior art, the advantages of applying the inductor of the utility model are reflected in the following aspects: the inductor connects the primary coil and the secondary coil, both of which are not insulated, through an insulating interlayer to form an isolated coil module. On the one hand, the withstand voltage between the two coils is greatly improved, which can reach more than 200V. At the same time, the assembly of the coil module and the magnetic core is simplified, and it is suitable for connection to an automated production line, thereby effectively improving production efficiency.

[0014] In addition, Ansys Maxwell simulation shows that the TLVR coupled inductor obtained by the improved structure has a higher coupling rate, and the coupling coefficient K is as high as 0.917789. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the decomposition and assembly structure of the TLVR coupled inductor of the utility model.

[0016] Figure 2 It is a schematic diagram of the simulation model of the TLVR coupled inductor of the utility model.

[0017] Figure 3 It is a schematic interface of simulation results of the TLVR coupled inductor of the utility model. DETAILED DESCRIPTION

[0018] In order to enable those skilled in the art to better understand the solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present application.

[0019] As is well known in the art, the conventional structure of a TLVR coupled inductor is composed of a primary coil, a secondary coil and a magnetic core, wherein the primary coil interacts with the magnetic core to generate a first inductance when powered on, and the secondary coil interacts with the magnetic core to generate a second inductance coupled to the first inductance when powered on; and while ensuring insulation between the two coils, the coupling ratio between them is an important performance parameter of the device. Figure 1 As shown, as a structural optimization of the inductor device, the preformed primary coil 1 and the secondary coil 2 are connected through an insulating interlayer to form an inner and outer nested coil module 4, and the two-pole coils of the coil module 4 are separated by an insulating interlayer 3; and the magnetic cores 5a and 5b wrap the coil module 4 and expose all the pins formed by bending the two-pole coils on the same side.

[0020] It needs to be explained in more detail that the primary coil 1 and the secondary coil 2 used in the TLVR coupled inductor of the utility model are both benign conductors without insulation coating (i.e., bare state). Therefore, the bending operation of the two-stage coils during their respective prefabrication molding processes will not need to worry about the insulation failure caused by surface damage. In order to achieve the insulation and coupling of the two during the assembly and packaging process of the TLVR coupled inductor product, the present application designs the prefabricated primary coil and the secondary coil to be formed into one piece through an insulating interlayer. Specifically, the two can be positioned as "inserts" in the injection molding cavity and injection molded with materials such as LCP or PPS, or can be directly produced with one mold and multiple cavities, and the obtained injection molded open loop is clamped in the gap between the two-stage coils and the two are reliably isolated, and the inter-stage withstand voltage is more than 200V. Therefore, it is only necessary to assemble the complete coil module and the magnetic core once, and then cooperate with mature processes such as dispensing, bonding, and baking glue, so that the TLVR coupled inductor finished product A can be easily encapsulated, and the production efficiency is significantly improved. Of course, as an optional implementation of the insulating interlayer, it can also be an epoxy colloid that is filled, bonded and cured between the two-stage coils.

[0021] As can be seen from the figure, the two ends of the prefabricated primary coil 1 are bent outward to form the first pin 11 and the fourth pin 12, while the two ends of the secondary coil 2 are bent inward to form the second pin 21 and the third pin 22 that are spaced apart from each other. And when the two-stage coil is completed by injection molding, the first pin 11 and the second pin 21 are spaced apart by the edge 31 of one side of the insulating interlayer, and the third pin 22 and the fourth pin 12 are spaced apart by the edge 32 of the other side of the insulating interlayer. In this way, not only the body of the two-stage coil formed in the magnetic core (or magnetic shell) can be reliably insulated, but also the exposed parts of the pins can achieve ideal insulation performance.

[0022] As shown in the preferred embodiment, the magnetic core is composed of two independently formed E-shaped magnetic shells 5a and 5b, and a mounting groove 51 suitable for positioning and filling the coil module is formed in the magnetic core in the spliced ​​and assembled state, and the outer wall spacing of the mounting groove is adapted to the primary coil, and the inner wall spacing of the mounting groove is adapted to the secondary coil sleeved thereon. The magnetic core can be formed by high-frequency and low-loss manganese-zinc ferrite powder or alloy iron powder by cold pressing, hot pressing, and high-temperature sintering, wherein the alloy iron powder is selected from one or a mixture of two or more of FeSiAl / FeNi / FeSi. Of course, in addition to the illustrated embodiment, the two parts of the magnetic core can also be a U-shaped magnetic shell and a T-shaped magnetic shell, and they are glued and spliced ​​into a magnetic shell structure consistent with the combination of the two E-shaped magnetic shells.

[0023] From the above detailed description of a preferred embodiment of a TLVR coupled inductor of the utility model, it can be seen that compared with the prior art, this solution has substantial characteristics and progress, and its technical effect is as follows: the inductor connects the primary coil and the secondary coil, both of which are not insulated, through an insulating interlayer to form an isolated coil module. On the one hand, the withstand voltage between the two coils is greatly improved, which can reach more than 200V. At the same time, it simplifies the assembly of the coil module and the magnetic core, and is suitable for connection to an automated production line, thereby effectively improving production efficiency.

[0024] In addition, if Figure 2 and Figure 3 As shown in the figure, Ansys Maxwell simulation shows that the TLVR coupled inductor obtained by the improved structure has a higher coupling rate, and the coupling coefficient K is as high as 0.917789.

[0025] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the principles of the present application shall be included in the protection scope of the present application.

Claims

1. A TLVR coupled inductor, which is composed of a primary coil, a secondary coil and a magnetic core, wherein the primary coil acts with the magnetic core to generate a first inductance when powered on, and the secondary coil acts with the magnetic core to generate a second inductance coupled with the first inductance when powered on, characterized in that: The preformed primary coil and secondary coil are connected through an insulating interlayer to form an inner and outer nested coil module, and the two-stage coils of the coil module are separated by an insulating interlayer; the magnetic core wraps the coil module and exposes all the pins formed by bending the two-stage coils on the same side.

2. The TLVR coupled inductor according to claim 1, characterized in that: The primary coil and the secondary coil are both bare benign conductors.

3. The TLVR coupled inductor according to claim 1, characterized in that: The insulating interlayer is a plastic open loop that is injection-molded between the two-stage coils, or an epoxy colloid that is filled, bonded and cured between the two-stage coils.

4. The TLVR coupled inductor according to claim 1, characterized in that: The two ends of the primary coil are bent outward to form a first pin and a fourth pin, and the two ends of the secondary coil are bent inward to form a second pin and a third pin that are separated from each other, and the first pin and the second pin are separated by an end edge on one side of the insulating interlayer, and the third pin and the fourth pin are separated by an end edge on the other side of the insulating interlayer.

5. The TLVR coupled inductor according to claim 1, characterized in that: The magnetic core is composed of two independently formed magnetic shells, and in the spliced ​​assembly state, a mounting groove suitable for positioning and loading the coil module is formed inside the magnetic core, the outer wall spacing of the mounting groove is adapted to accommodate the primary coil therein, and the inner wall spacing of the mounting groove is adapted to accommodate the secondary coil thereon.

6. The TLVR coupled inductor according to claim 1 or 5, characterized in that: The magnetic core is composed of a U-shaped magnetic shell and a T-shaped magnetic shell, or is composed of two E-shaped magnetic shells with the same appearance.

7. The TLVR coupled inductor according to claim 1 or 5, characterized in that: The magnetic core is a molded body made of manganese-zinc ferrite powder or alloy iron powder.

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