TLVR inductor with double flat wires wound in parallel

Abstract

The utility model discloses a TLVR inductor wound by double flat wires in parallel, the inductor comprises a T-shaped magnetic core, a primary coil and a secondary coil, the T-shaped magnetic core is a magnet which is integrally formed by mould pressing and is provided with a bottom plate and a stand column, the two coils which are respectively wrapped in an insulating mode are formed into more than one turn of concentric thread-shaped coil through double-wire winding, and the primary coil and the secondary coil are arranged in the T-shaped magnetic core. Two ends of the two coils are respectively bent towards the same side to form a first opening and a second opening which are sleeved inside and outside, the T-shaped magnetic core and the two coils are packaged and molded into a rectangular block body by hot-pressing powder in a combined state, and two groups of pins are molded based on the end parts of the two coils. According to the TLVR inductor, the two stages of coils which are different in thickness and are insulated and separated are spirally wound in parallel and are connected with the T-shaped magnetic core in a sleeved mode to be assembled and then packaged, the insulation isolation and coupling rate between the two stages of coils can be improved, the coupling coefficient K can reach 0.7, the transient response of the type of inductor is improved, and the TLVR inductor has the advantages of being simple in structure and convenient to use. The method is widely applied to hot industries such as AI artificial intelligence, ChatGPT, big data, cloud service and the like.

Description

Technical Field

[0001] The utility model relates to an inductor device, in particular to a TLVR inductor with double flat wires wound in parallel, belonging to the technical field of basic electronic components. Background Art

[0002] Inductors are one of the most commonly used components in electronic devices, widely used in various circuits to achieve filtering, energy storage, matching, and resonance. With the increasing miniaturization and portability of electronic products and the high-density assembly of components, the use of inductors has rapidly developed. Furthermore, due to electromagnetic compatibility considerations, the ability of electronic products to resist electromagnetic interference has become a fundamental design requirement, thus increasing the demand for 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 traditional DC-to-DC buck (step-down) and DC (direct current) architectures is that the TLVR inductor replaces the traditional single-winding inductor with a dual-winding transformer-like inductor. While a conventional inductor has only one set of windings and two pins, a TLVR inductor has two sets of mutually coupled windings and four pins, resulting in significant structural differences between the two.

[0004] However, in the current industry, when designing the structure of TLVR inductors, the magnetic core and the primary and secondary coils are loosely assembled, which can easily damage the insulation isolation. Figure 7 As shown, potential voltage buildup between the primary and secondary windings, depending on the circuit stage, is observed at the application end. This places higher insulation isolation requirements on TLVR inductors. Meeting these performance requirements requires further optimization of the inductor's internal structure. Summary of the Invention

[0005] In view of the above-mentioned defects in the prior art, the purpose of the present invention is to provide a TLVR inductor with two flat wires wound in parallel, which improves the performance of the finished product and the yield rate of the processing production by optimizing the internal structure of the device.

[0006] The technical solution for achieving the above-mentioned purpose of the present invention is to include a T-shaped magnetic core, a primary coil and a secondary coil, and is characterized in that: the T-shaped magnetic core is a magnet formed by molded integrally, and has a rectangular bottom plate and a column at the center thereof, the primary coil and the secondary coil, each of which is insulated and wrapped, are formed into concentric threaded coils with more than one turn by double-wire winding, and the two ends of the primary coil are bent toward the same side to provide a first opening, and the two ends of the secondary coil are bent toward the same side to form a second opening compatible with the first opening, the column of the T-shaped magnetic core is connected to the connecting hole formed by the threaded coil, the second opening is bent toward the center of the bottom plate and embraces the bottom plate, and the first opening is bent in the opposite direction to the second opening; when the T-shaped magnetic core and the two coils are combined, they are encapsulated into a rectangular block by hot-pressing powder, and two groups of pins are formed based on the ends of the two coils.

[0007] Furthermore, the base plate is provided with a pair of notched grooves at two corners along a diagonal line thereof, and the second opening is passed through the notched grooves and bent toward the center, non-closedly embracing the base plate, and the first opening of the primary coil is compatible with the notched grooves and bent toward the diagonal extension direction.

[0008] Furthermore, the surface of the encapsulated rectangular block is spray-painted with an insulating coating, and the paint is stripped and electroplated at the end corresponding to the bending of the primary coil to form the first pin and the second pin, and the paint is stripped and electroplated at the end corresponding to the bending of the secondary coil to form the third pin and the fourth pin.

[0009] Furthermore, the first pin and the second pin are formed as the short side Pad of the bottom surface of the rectangular block, and the third pin and the fourth pin are formed as the midpoint Pad of the long side of the bottom surface of the rectangular block.

[0010] Furthermore, the thickness of the primary coil is greater than that of the secondary coil, and the DC resistance ratio of the secondary coil to the primary coil is between 3 and 5; in the packaged state, the insulation isolation between the two coils is maintained above DC 150V.

[0011] Compared with existing technologies, the advantages of the TLVR inductor of this invention are reflected in the following: the inductor utilizes two coils of different thicknesses and insulation separation, which are spirally wound and then sleeved onto a T-shaped magnetic core for assembly and packaging. In particular, the relatively compact axial connection of the two coils and their facing-to-T-shaped core connection facilitate the assembly to maintain a stable state during hot pressing packaging, further improving the insulation isolation and coupling ratio between the two coils, with a coupling coefficient K of up to 0.7, and improving the transient response of this type of inductor. This makes it more suitable for hardware manufacturing in popular industries such as AI, ChatGPT, big data, and cloud services. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1It is a structural diagram of the primary coil of the TLVR inductor of the utility model.

[0013] Figure 2 It is a structural schematic diagram of the secondary coil of the TLVR inductor of the present invention.

[0014] Figure 3 This is a schematic diagram of the assembly of the TLVR inductor of the present invention before packaging.

[0015] Figure 4 This is a schematic diagram of the bottom structure of a rectangular block obtained during the manufacturing process of the TLVR inductor of the utility model.

[0016] Figure 5 This is a schematic diagram of the bottom structure of a finished product of the TLVR inductor of the utility model.

[0017] Figure 6 This is the coupling rate result obtained by simulation of the TLVR inductor of the utility model.

[0018] Figure 7 This is a schematic diagram analyzing the potential voltage in current conductive inductor regulator applications. DETAILED DESCRIPTION

[0019] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of this application.

[0020] To address the issue of potential voltage at the application end, which can lead to insulation breakdown and failure in conventional dual-coil coupled inductors used in conductive inductor voltage regulators, the designers of this utility model have innovatively proposed a TLVR inductor with two parallel windings of flat wire. By optimizing the device's internal structure, this device improves both finished product performance and manufacturing yield. The specific solution is as follows.

[0021] like Figures 1 to 6As shown, the double flat wire parallel wound TLVR inductor is mainly composed of three parts: a T-shaped core, a primary coil and a secondary coil, which are assembled and packaged and finalized before the pins are customized and the finished product is discharged. As the main innovative feature, the utility model mainly optimizes and adjusts the external structure of the three parts assembled with each other to be more adaptive. In summary, the T-shaped core 1 is a magnet molded as one piece, and has a rectangular base plate 11 and a column 12 at the center. The primary coil 2 and the secondary coil 3 are both benign conductors with insulating coatings, and are formed into concentric threaded coils with more than one turn by double wire parallel winding. The two ends of the primary coil are bent toward the same side to provide a first opening 22, and the two ends of the secondary coil are bent toward the same side to form a second opening 32 compatible with the first opening. When the primary coil 2 and the secondary coil 3 are pre-assembled, the above-mentioned column 12 is connected to the connecting hole formed by the two parts of the coil (not marked, see for details). Figure 3 As shown in the middle, the two ends of the secondary coil 3 are bent relative to each other and connected to the bottom plate. The bending direction of each end of the primary coil is opposite to that of the adjacent secondary coil. Figure 3 As shown in the middle. It should be noted that the aforementioned end bends occur after the coils are assembled with the T-shaped core. The T-shaped core and two coils are then assembled in a custom mold using hot-pressed powder and resin filling and encapsulation to form a rectangular block. Two sets of pins are formed at the ends of the two coils.

[0022] To facilitate assembly and increase the spacing between the bent ends, the base plate 11 is provided with a pair of notches 13a and 13b at its two corners along a diagonal line. The second opening 32 of the secondary coil 3 extends through the notches and bends toward the center, forming a non-closed embrace with the base plate 11. The first opening 22 of the primary coil 2 fits within the notches and bends outward diagonally.

[0023] From a further perspective of detailed features, the above-mentioned packaged rectangular block needs to undergo surface painting treatment after the product is discharged, and an insulating coating is formed on its surface. The paint is stripped at the end corresponding to the bend of the primary coil, and the first pin 23a and the second pin 23b are formed by electroplating. The paint is stripped at the end corresponding to the bend of the secondary coil, and the third pin 33a and the fourth pin 33b are formed by electroplating. Before the TLVR inductor is discharged as a finished product, each pin needs to be electroplated to meet the application and assembly of circuit board soldering. In view of the linear distribution of the aforementioned pins along the diagonal line, the electroplating operation has diversified operability. For example, Figure 5As can be seen in the preferred embodiment shown, the first and second pins 23a and 23b can be formed as the short side Pad5 of the bottom surface of the rectangular block, while the third and fourth pins 33a and 33b can be further redirected to form the midpoint Pad6 of the long side of the bottom surface of the rectangular block. Alternatively, the first, second, third, and fourth pins 23a and 23b can be directly formed as the four parallel and spaced short side Pads on the bottom surface of the rectangular block. Although the appearance is identical, the relatively outer pair of short side Pads corresponds to the signal transmission of the primary coil, while the relatively inner pair of short side Pads corresponds to the signal transmission of the secondary coil.

[0024] In addition, it can be seen from the figure and should be noted that the thickness of the primary coil is higher than that of the secondary coil, and the DC resistance ratio of the secondary coil to the primary coil is between 3 and 5; in the packaged state, the insulation isolation between the two coils is maintained above DC150V, which is more resistant to Figure 7 The circuit shown builds up potential voltage in stages.

[0025] The optimization of the TLVR inductor's internal structure can further explain its production process. A brief description is as follows:

[0026] S1. Prefabricate the preformed parts before assembly. Prefabricate a first mold corresponding to the T-shaped magnetic core and a second mold corresponding to the finished inductor according to the specifications and dimensions. Then fill the first mold with magnetic powder and mold it to obtain a single part.

[0027] S2. Insulated conductive metal strips and flat wires are taken according to the specifications and wound in parallel to form a spiral coil with at least one concentric and alternating turns. The coils are then bent so that the first opening of the primary coil and the second opening of the secondary coil are substantially coplanar and overlap.

[0028] S3. Insert the column of the T-shaped magnetic core into the connecting hole in the center of the assembly obtained in S2 from the opening direction, and place the bottom plate of the T-shaped magnetic core against one of the two coils. Then bend the second opening inward to embrace the bottom plate, and bend the first opening outward.

[0029] S4. Position the semi-finished product assembly of S3 in a second mold, fill the second mold with hot pressing powder and resin, and encapsulate it under a preset temperature and pressure to obtain a rectangular block with TLVR inductor function.

[0030] S5. The rectangular block obtained in S4 is spray-painted, and the ends of the two coils are stripped and electroplated to form two sets of pins.

[0031] When implementing the above-mentioned manufacturing method, the magnetic powder material in S1 is one, or a mixture of two or more of FeSiAl, FeNi, FeSiCr, or iron-based amorphous or nanocrystalline materials, and the molding pressure is between 8 tons / cm² and 16 tons / cm². It is baked at 120-200°C for 2-4 hours to strengthen and set the shape. The hot-pressed powder material added to the second mold in S4 is one, or a mixture of two or more of FeSiAl, FeNi, FeSiCr, or iron-based amorphous or nanocrystalline materials, and is uniformly mixed with epoxy resin, silicone resin, or acrylic resin. The packaging parameters include a molding temperature between 100-200°C and a molding pressure between 15 tons / cm² and 25 tons / cm².

[0032] From the above introduction and detailed description of the embodiment of the TLVR inductor with double flat wires wound in parallel, it can be seen that compared with the existing technology, this solution has substantial characteristics and progress, and its technical effect is as follows: the inductor uses two-stage coils of different thicknesses and insulation separation to be spirally embedded and assembled with a T-shaped magnetic core sleeve and then packaged. In particular, the two-stage coils are relatively compactly combined in the axial direction and are hugged facing the T-shaped magnetic core, which is conducive to maintaining a stable state for hot pressing packaging of the assembly and is more conducive to improving the insulation isolation and coupling rate between the two-stage coils. Figure 6 The simulation results show that the coupling coefficient K of this TLVR inductor can reach over 0.7, improving the transient response of this type of inductor. This allows for better application in hardware manufacturing in popular industries such as AI, ChatGPT, big data, and cloud services.

[0033] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Various modifications and variations are possible for those skilled in the art. Any modifications, equivalent substitutions, improvements, etc. made within the principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A TLVR inductor with double flat wires wound in parallel, comprising a T-shaped magnetic core, a primary coil and a secondary coil, characterized in that: The T-shaped magnetic core is a magnet formed by molding as one piece, and has a rectangular bottom plate and a column at the center thereof. The primary coil and the secondary coil, each of which is insulated and wrapped, are formed into concentric threaded coils with more than one turn by double wire winding, and the two ends of the primary coil are bent toward the same side to provide a first opening, and the two ends of the secondary coil are bent toward the same side to form a second opening compatible with the first opening. The column of the T-shaped magnetic core is connected to the connecting hole formed by the threaded coil, and the second opening is bent toward the center of the bottom plate and embraces the bottom plate, and the first opening is bent in the opposite direction to the second opening; when the T-shaped magnetic core and the two coils are combined, they are encapsulated into a rectangular block by hot pressing powder, and two groups of pins are formed based on the ends of the two coils.

2. The TLVR inductor with double flat wires wound in parallel according to claim 1, characterized in that: The bottom plate is provided with a pair of notches at two corners along a diagonal line thereof, and the second opening is passed through the notches and bent toward the center, non-closedly embracing the bottom plate, and the first opening of the primary coil is compatible with the notches and bent toward the diagonal extension direction.

3. The TLVR inductor with double flat wires wound in parallel according to claim 1, characterized in that: The surface of the packaged rectangular block is spray-painted with an insulating coating, and the paint is stripped and electroplated at the end corresponding to the bending of the primary coil to form the first pin and the second pin, and the paint is stripped and electroplated at the end corresponding to the bending of the secondary coil to form the third pin and the fourth pin.

4. The TLVR inductor with double flat wires wound in parallel according to claim 3, characterized in that: The first pin and the second pin are formed as the short side Pad of the bottom surface of the rectangular block, and the third pin and the fourth pin are formed as the midpoint Pad of the long side of the bottom surface of the rectangular block.

5. The TLVR inductor with double flat wires wound in parallel according to claim 1, characterized in that: The thickness of the primary coil is greater than that of the secondary coil, and the DC resistance ratio of the secondary coil to the primary coil is between 3 and 5; in the packaged state, the insulation isolation between the two coils is maintained above DC 150V.

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