Inductor

Abstract

The utility model relates to the technical field of inductors, a magnet yoke column of the inductor is arranged on one side of a first magnetic core column in a third direction, a magnetic path between the magnet yoke column and the first magnetic core column and a magnetic path between the magnet yoke column and a second magnetic core column are conducted through an end portion magnet yoke, the first magnetic core column and the second magnetic core column are arranged along a first direction, and the first direction is perpendicular to the second direction. The first direction is perpendicular to the third direction, so that in the first direction, namely the width direction of the inductor, the size of the inductor is reduced, the overall size of the inductor is more compact, and the inductor can be better suitable for occasions where the width size of the inductor is smaller. In addition, after the magnet yoke columns are arranged side by side, the magnetic flux area can be increased in a limited space.

Description

Technical Field

[0001] The utility model relates to the technical field of inductors, in particular to an inductor with a yoke column placed beside it. Background Art

[0002] High-power automotive inductors are used in automotive power supply systems. Current boost inductors typically consist of two inductor coils, a magnetic core, and a yoke. The core is located within the coils, while the yoke is located outside. The yoke is typically positioned between the two cores, resulting in a larger gap between the two cores and a wider inductor body. This makes it less suitable for applications requiring a narrower inductor body. Utility Model Content

[0003] The utility model provides an inductor which can be better applied to the occasions requiring smaller width of the inductor body.

[0004] In a first aspect, an embodiment provides an inductor, comprising a first inductor coil, a second inductor coil, a first magnetic core leg, a second magnetic core leg, a yoke leg, and an end yoke; the first inductor coil is enclosed around the first magnetic core leg with a first insulator filled therebetween, the second inductor coil is enclosed around the second magnetic core leg with a second insulator filled therebetween, the end yoke is located at an end of the yoke leg, and the magnetic paths between the yoke leg and the first magnetic core leg and between the yoke leg and the second magnetic core leg are both conducted through the end yoke;

[0005] The first magnetic core column and the second magnetic core column are arranged in a first direction, the first magnetic core column, the second magnetic core column and the yoke column all extend along the second direction, and the first direction is perpendicular to the second direction; the first direction and the second direction are both perpendicular to a third direction, and the yoke column is arranged on one side of the first magnetic core column in the third direction.

[0006] Furthermore, in one embodiment, the first magnetic core column end, the second magnetic core column end and the yoke column end are all magnetically conductive with the end magnetic yoke; the end magnetic yoke includes a first magnetic core column conductive surface that is magnetically conductive with the first magnetic core column, a second magnetic core column conductive surface that is magnetically conductive with the second magnetic core column and a yoke column conductive surface that is magnetically conductive with the yoke column, the first magnetic core column conductive surface is perpendicular to the yoke column conductive surface, and the first magnetic core column conductive surface and the second magnetic core column conductive surface are both on one side of the end magnetic yoke in the second direction.

[0007] Furthermore, in one embodiment, the inductor includes a yoke column insulator, the yoke column insulator is covered on the yoke column, and the side of the first inductor coil facing the yoke column and the side of the second inductor coil facing the yoke column are both in contact with the yoke column insulator.

[0008] Furthermore, in one embodiment, the side surface of the first inductor coil facing away from the yoke column and the side surface of the second inductor coil facing away from the yoke column are both exposed heat dissipation surfaces, and the heat dissipation surfaces are used to fit with a thermal pad for heat dissipation.

[0009] Furthermore, in one embodiment, the inductor includes an inductor insulator, which fixes the yoke column, the end yoke, the first magnetic core column and the second magnetic core column, and the inductor insulator includes an extrusion protrusion protruding toward the third direction, and the extrusion protrusion is arranged on the periphery of the heat dissipation surface to squeeze the thermal pad to cause the thermal pad to be recessed.

[0010] Furthermore, in one embodiment, the yoke column is in the shape of a flat plate.

[0011] Furthermore, in one embodiment, the yoke column includes a first column and a second column, the first column and the second column are arranged along a first direction, the first column and the second column are in contact with each other, or the first column and the second column are arranged at intervals along the first direction and form a column gap, the inductor includes an inductor lead, and at least one of the inductor leads and / or the terminal of the first inductor coil and / or the terminal of the second inductor coil passes through the column gap.

[0012] Furthermore, in one embodiment, the inductor is a magnetically integrated interleaved parallel inductor, and the first inductor coil and the second inductor coil are connected in parallel.

[0013] Furthermore, in one embodiment, the inductor includes a first inductor insulator and a second inductor insulator, the first inductor insulator and the second inductor insulator are arranged at intervals in the extension direction of the yoke column, at least one end yoke is a first yoke magnetically connected to one end of the yoke column, and at least one end yoke is a second yoke magnetically connected to the other end of the yoke column; the first inductor insulator fixes one end of the yoke column to the first yoke, and the second inductor insulator fixes the other end of the yoke column to the second yoke.

[0014] Furthermore, in one embodiment, the first inductor insulator includes a surface portion covering the outer surface of the first magnetic yoke and an inner portion located on the side of the first magnetic yoke facing the first magnetic core column, and the inner portion is connected to the surface portion; in the extension direction of the first magnetic core column, at least a portion of the inner portion is located between the first insulator and the end magnetic yoke.

[0015] According to the inductor of the above embodiment, the yoke post is arranged on one side of the first magnetic core post in the third direction. The magnetic paths between the yoke post and the first magnetic core post, and between the yoke post and the second magnetic core post, are both conducted through the end yokes. The first and second magnetic core posts are arranged along a first direction perpendicular to the third direction. This reduces the width of the inductor body in the first direction, i.e., the width of the inductor, making the overall inductor more compact and better suited for applications requiring a smaller inductor width. Furthermore, the side-by-side placement of the yoke post increases the magnetic flux area within a limited space. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a schematic structural diagram of an inductor in one embodiment;

[0017] Figure 2 is another structural schematic diagram of an inductor in one embodiment;

[0018] Figure 3 is a schematic structural diagram of an inductor and a thermal pad assembled together in one embodiment;

[0019] Figure 4 is a cross-sectional view of an inductor in one embodiment;

[0020] Figure 5 is another cross-sectional view of an inductor in one embodiment;

[0021] Figure 6 is a cross-sectional view of an inductor from another perspective in an embodiment;

[0022] Figure 7 FIG1 is a schematic structural diagram of an inductor in an embodiment after the inductor insulator is hidden;

[0023] Figure 8 is another structural schematic diagram of an inductor in an embodiment after the inductor insulator is hidden;

[0024] Figure 9 A schematic structural diagram of a yoke column assembly in one embodiment;

[0025] Figure 10 An exploded view of the first assembly, the second assembly, and the pre-positioning member in one embodiment;

[0026] Figure 11 is a schematic structural diagram of a first inductor insulator in an embodiment;

[0027] Figure 12 A schematic structural diagram of a yoke column and an end yoke in one embodiment;

[0028] Figure 13 FIG. 4 is a schematic structural diagram of another inductor in an embodiment.

[0029] List of feature names corresponding to the reference numerals in the figures: 1. first assembly; 11. first inductor coil; 12. first magnetic core column; 121. magnetic core block; 122. ceramic sheet; 13. first insulator; 2. yoke column assembly; 21. yoke column; 211. first column; 212. second column; 213. column spacer; 22. yoke column insulator; 221. first positioning structure; 2211. first positioning groove; 222. second positioning structure; 2221. second positioning groove; 3. inductor insulator; 31. first inductor insulator; 311. surface portion; 312. inner portion; 3121. first inner portion; 31 22. Second inner portion; 32. Second inductor insulator; 33. Extrusion protrusion; 321. Injection molded portion of conductive bar; 4. End yoke; 41. Conductive surface of first magnetic core column; 42. Conductive surface of second magnetic core column; 43. Conductive surface of yoke column; 5. Second assembly; 51. Second inductor coil; 52. Second magnetic core column; 53. Second insulator; 6. Inductor lead; 61. Wiring conductive bar; 611. First wiring conductive bar; 7. Mounting insert; 71. Mounting hole; 8. Thermal pad; 10. Pre-positioning member; 101. Protrusion; 102. Positioning hole; 103. Inductor copper bar; 1031. Input terminal; 1032. Output terminal.

[0030] Explanation of the reference numerals in brackets in the accompanying drawings: In the reference numerals in brackets in the accompanying drawings, the features referred to by the reference numerals are both the features represented by the numbers in the brackets and the features represented by the numbers outside the brackets. DETAILED DESCRIPTION

[0031] The present invention is further described in detail below by means of specific embodiments in conjunction with the accompanying drawings. Similar elements in different embodiments are numbered with associated similar elements. In the following embodiments, many detailed descriptions are provided to enable the present application to be better understood. However, those skilled in the art will readily appreciate that some of the features may be omitted under different circumstances, or may be replaced by other elements, materials, or methods. In some cases, some operations related to the present application are not shown or described in the specification. This is to avoid the core portion of the present application being overwhelmed by excessive descriptions. For those skilled in the art, it is not necessary to describe these related operations in detail. They can fully understand the related operations based on the description in the specification and the general technical knowledge in the art.

[0032] In addition, the features, operations, or characteristics described in the specification may be combined in any appropriate manner to form various embodiments. Furthermore, the steps or actions in the method description may be reordered or adjusted in a manner readily apparent to those skilled in the art. Therefore, the various sequences in the specification and drawings are provided solely for the purpose of clearly describing a particular embodiment and are not intended to be mandatory, unless otherwise specified.

[0033] The serial numbers assigned to components herein, such as "first," "second," etc., are used solely to distinguish the objects being described and do not convey any sequential or technical meaning. References to "connection" and "coupling" herein, unless otherwise specified, include both direct and indirect connections (couplings).

[0034] In one embodiment, please refer to Figures 1 to 12 The inductor includes a first inductor coil 11 , a second inductor coil 51 , a first magnetic core column 12 , a second magnetic core column 52 , a yoke column 21 and an end yoke 4 .

[0035] The first inductor 11 is wrapped around the first magnetic core 12 and a first insulator 13 is filled between the first inductor 11 and the second inductor 51 is wrapped around the second magnetic core 52 and a second insulator 53 is filled between the first inductor 11 and the second insulator 53. Figures 1 to 6 The first inductor 11 is sheathed around the first magnetic core leg 12, with a gap between the first inductor 11 and the first magnetic core leg 12. The first insulator 13 secures the first inductor 11 and the first magnetic core leg 12. At least a portion of the first insulator 13 fills the gap between the first inductor 11 and the first magnetic core leg 12. The second inductor 51 is sheathed around the second magnetic core leg 52, with the second insulator 53 securing the second inductor 51 and the second magnetic core leg 52, and at least a portion of the second insulator 53 fills the gap between the second inductor 51 and the second magnetic core leg 52.

[0036] The end yoke 4 is located at the end of the yoke column 21, and the magnetic paths between the yoke column 21 and the first magnetic core column 12, and between the yoke column 21 and the second magnetic core column 52, are both conducted through the end yoke 4. It should be noted that the yoke column 21 and the end yoke 4 are both located outside the first inductor 11 and within the second inductor 51, serving to conduct the magnetic paths.

[0037] The first magnetic core leg 12 and the second magnetic core leg 52 are arranged in a first direction. The first magnetic core leg 12, the second magnetic core leg 52, and the yoke leg 21 all extend in a second direction, with the first direction being perpendicular to the second direction. The first and second directions are both perpendicular to a third direction, and the yoke leg 21 is arranged on one side of the first magnetic core leg 12 in the third direction.

[0038] The yoke column 21 of the inductor is arranged on one side of the first magnetic core column 12 in the third direction, that is, the yoke column 21 is arranged in a side-by-side manner. The magnetic paths between the yoke column 21 and the first magnetic core column 12 and the magnetic paths between the yoke column 21 and the second magnetic core column 52 are both conducted through the end yoke 4. The first magnetic core column 12 and the second magnetic core column 52 are arranged along the first direction, which is perpendicular to the third direction. In this way, in the first direction, which is the width direction of the inductor, the width of the inductor body is reduced, and the overall size of the inductor is more compact, which can better adapt to occasions where the inductor width is smaller. In addition, after the yoke column 21 is placed side by side, the magnetic flux area can be increased within a limited space. The width dimension of the inductor body is the dimension of the space occupied by the first magnetic core column 12 and the second magnetic core column 52 in the first direction. The dimension of the yoke column 21 in the first direction is smaller than the dimension of the space occupied by the first magnetic core column 12 and the second magnetic core column 52 in the first direction.

[0039] In one embodiment, the first inductor 11 and the second inductor 51 are connected in parallel, and the inductor is a magnetically integrated staggered parallel inductor. After magnetic integration, the size and weight are smaller than those of two single inductors.

[0040] In one embodiment, the yoke column 21 is arranged in a side-by-side manner, and magnetic paths are formed between the yoke column 21 and the first magnetic core column 12, between the yoke column 21 and the second magnetic core column 52, and between the first magnetic core column 12 and the second magnetic core column 52, so that the inductor forms a three-dimensional magnetic path in a three-dimensional space.

[0041] Specifically, in one embodiment, please refer to Figure 4 , the first insulator 13 is completely filled in the gap between the first inductor 11 and the first magnetic core 12. In one embodiment, please refer to Figure 4The first insulator 13 partially fills the space between the first inductor 11 and the first magnetic core 12, and partially extends over the portion of the first magnetic core 12 extending beyond the first inductor 11. In another embodiment, the first insulator 13 may extend to the outer surface of the first inductor 11, thereby covering at least a portion of the outer surface of the first inductor 11.

[0042] In one embodiment, please refer to Figures 1 to 6 The inductor includes an inductor insulator 3, which secures the yoke column 21, the end yoke 4, the first magnetic core column 12, and the second magnetic core column 52. Specifically, the inductor insulator 3 is injection molded. In some other embodiments, the inductor insulator 3 can also be molded after curing the potting compound, or can be injection molded first and then assembled with other components.

[0043] In one embodiment, please refer to Figure 6 The inductor includes a yoke column insulator 22, which covers the yoke column 21. Specifically, in one embodiment, the yoke column insulator 22 is injection-molded on the yoke column 21.

[0044] The first insulator 13 , the yoke column insulator 22 and the inductor insulator 3 may all be made of any feasible material. Typically, the first insulator 13 , the yoke column insulator 22 and the inductor insulator 3 are all made of insulating materials.

[0045] The insulator involved in this application can be formed in any feasible way, such as injection molding, potting molding, and the insulator can be directly molded together with other parts by injection molding, or it can be pre-injection molded and then assembled with other parts if permitted.

[0046] Regarding the first magnetic core column 12, in one embodiment, please refer to Figure 4 and Figure 6 The first magnetic core column 12 includes at least two stacked magnetic core blocks 121, with ceramic sheets 122 between adjacent magnetic core blocks 121. Specifically, in one embodiment, there are four magnetic core blocks 121 and three ceramic sheets 122, wherein the ceramic sheets 122 are made of magnetically conductive ceramic.

[0047] Further, in one embodiment, please refer to Figures 4 to 6The end of the first magnetic core leg 12, the end of the second magnetic core leg 52, and the end of the yoke leg 21 are all magnetically conductive with the end yoke 4. The end yoke 4 includes a first magnetic core leg conductive surface 41, a second magnetic core leg conductive surface 42, and a yoke leg conductive surface 43. The first magnetic core leg conductive surface 41 is perpendicular to the yoke leg conductive surface 43. The first magnetic core leg conductive surface 41 and the second magnetic core leg conductive surface 42 are located on one side of the end yoke 4 in the second direction. In this way, the end yoke 4 is respectively attached to the magnetic core leg and the yoke leg 21 through different side surfaces, which can ensure that the end yoke 4 is tightly attached to the yoke leg 21 and the magnetic core leg.

[0048] Further, in one embodiment, please refer to Figure 1 and Figure 6 The side surface of the first inductor coil 11 facing the yoke column 21 and the side surface of the second inductor coil 51 facing the yoke column 21 are both in contact with the yoke column insulator 22 .

[0049] Furthermore, in one embodiment, please refer to Figure 3 and Figure 6 The side surface of the first inductor 11 facing away from the yoke column 21 and the side surface of the second inductor 51 facing away from the yoke column 21 are both exposed heat dissipation surfaces, which are used to fit with the thermal pad for heat dissipation.

[0050] In this way, the side of the first inductor coil 11 that is in contact with the yoke column insulator 22 can dissipate heat through the yoke column 21, and the side of the first inductor coil 11 that is away from the yoke column 21 can dissipate heat through the thermal pad 8. Similarly, the second inductor coil 51 can also dissipate heat through the yoke column insulator 22 and the thermal pad 8, so that the heat dissipation performance of the inductor is better.

[0051] Furthermore, in one embodiment, please refer to Figures 1 to 3 The inductor insulator 3 includes an extrusion protrusion 33 protruding toward the third direction. The extrusion protrusion 33 is arranged on the periphery of the heat dissipation surface to squeeze the thermal pad to make the thermal pad concave.

[0052] In one embodiment, please refer to Figures 1 to 3 In order to ensure the relative position stability of the thermal pad 8 and the coil, the inductor insulator 3 has an extrusion protrusion 33. After the coil and the thermal pad 8 come into contact, the extrusion protrusion 33 squeezes the thermal pad 8, forming a depression on the thermal pad 8. The extrusion protrusion 33 extends into the depression, which can limit the movement of the thermal pad 8, thereby preventing the thermal pad 8 from moving relative to the coil.

[0053] Further, in one embodiment, please refer to Figures 8 and 9 The yoke column 21 is in a flat plate shape. This helps reduce the thickness of the yoke column 21 and the volume of the inductor, and also helps increase the heat dissipation area, so that the heat can be dissipated quickly after being conducted to the yoke column 21.

[0054] Further, in one embodiment, please refer to Figure 2 and Figure 6 The inductor insulator 3 includes a first inductor insulator 31 and a second inductor insulator 32. The first and second inductor insulators 31 and 32 are spaced apart in the direction of extension of the yoke column 21. At least one end yoke 4 is a first yoke that is magnetically conductive with one end of the yoke column 21, and at least one end yoke 4 is a second yoke that is magnetically conductive with the other end of the yoke column 21. The first inductor insulator 3 secures one end of the yoke column 21 to the first yoke, while the second inductor insulator 3 secures the other end of the yoke column 21 to the second yoke. This reduces the footprint of the inductor insulator 3, allowing for a larger exposed area of ​​the coil and improving heat dissipation performance.

[0055] Further, in one embodiment, please refer to Figure 6 The first inductor insulator 31 is injection molded on one end of the yoke column 21 , and the second inductor insulator 32 is injection molded on the other end of the yoke column 21 .

[0056] In one embodiment, please refer to Figure 1 and Figure 2 The inductor's wiring conductive bar 61 is led out from the first inductor insulator 31 and the second inductor insulator 32. This allows the side of the yoke column insulator 22 facing away from the first inductor coil 11 to be a plane that can contact the thermal pad 8. At the same time, the side of the first inductor coil 11 facing away from the yoke column 21 and the side of the second inductor coil 51 facing away from the yoke column 21 are both planes that can contact the thermal pad 8. The inductor can use two parallel thermal pads 8 for heat dissipation, which has better heat dissipation capabilities. Of course, the heat dissipation surface that can contact the thermal pad 8 described in this application can also dissipate heat outward without using the thermal pad 8.

[0057] In one embodiment, please refer to Figure 12 The yoke column 21 includes a first column 211 and a second column 212 , and the first column 211 and the second column 212 are arranged along a first direction.

[0058] In one embodiment, please refer to Figure 12The first column 211 and the second column 212 are spaced apart in a first direction, and a column gap 213 is formed between the first column 211 and the second column 212. The inductor includes an inductor lead 6. At least one inductor lead 6 and / or the terminal of the first inductor coil 11 and / or the terminal of the second inductor coil 51 pass through the column gap 213. The column gap 213 facilitates wiring and can also achieve the arrangement of the yoke column 21 on the same side of the first magnetic core column 12 and the second magnetic core column 52 without affecting the coil routing. In some embodiments, the inductor lead 6 can be either a wiring conductive bar 61 connected to the coil or a signal line for transmitting signals.

[0059] Specifically, when the yoke column insulator 22 is injection-molded on the yoke column 21 , the first column 211 and the second column 212 are injection-molded respectively. The yoke column insulator 22 includes a first injection-molded portion on the first column 211 and a second injection-molded portion on the second column 212 .

[0060] In one embodiment, please refer to Figure 13 The first inductor 11 and the second inductor 21 are connected in parallel. The inductor includes an inductor copper busbar 103. At least a portion of at least one inductor copper busbar 103 is located within the column space 213. In one embodiment, the inductor has one input terminal 1031 and two output terminals 1032.

[0061] In one embodiment, please refer to Figure 9 The first column 211 and the second column 212 can also be fitted together, and in this case, the column spacer 213 is no longer required. In some other embodiments, the yoke column 21 is an integrated structure. In some other embodiments, the yoke column 21 can also be formed by stacking multiple magnetic core blocks 121.

[0062] Specifically, in one embodiment, please refer to Figure 4 、 Figure 5 and Figure 11 To improve the stability of the first inductor insulator 31, the first inductor insulator 31 includes a surface portion 311 covering the outer surface of the end yoke 4 and an inner portion 312 located on the side of the end yoke 4 facing the first magnetic core leg 12. The inner portion 312 is connected to the surface portion 311. In the extension direction of the first magnetic core leg 12, at least a portion of the inner portion 312 is located between the first insulator 13 and the end yoke 4. The inner portion 312 can better prevent the first inductor insulator 31 from separating from the end yoke 4.

[0063] In one embodiment, please refer to Figure 2 A mounting insert 7 is embedded in the insulator 3 of the inductor. The mounting insert 7 has a mounting hole 71. The mounting hole 71 is used to install the inductor to a target position.

[0064] In one embodiment, please refer to Figure 4 、 Figure 5 and Figure 11 The inner portion 312 comprises two parts: a first inner portion 3121 and a second inner portion 3122. In the arrangement direction of the first magnetic core leg 12 and the second magnetic core leg 52, the first inner portion 3121 is located between the first magnetic core leg 12 and the second magnetic core leg 52. In the arrangement direction of the yoke leg 21 and the first magnetic core leg 12, the second inner portion 3122 is located on the side of the yoke leg 21 facing the first magnetic core leg 12. Both ends of the second inner portion 3122 are connected to the surface portion 311. One end of the first inner portion 3121 is connected to the second inner portion 3122, and the other end is connected to the surface portion 311.

[0065] In one embodiment, based on the same concept, the structure of the second inductor insulator 32 is similar to that of the first inductor insulator 31 , and will not be described in detail.

[0066] In one embodiment, the inductor insulator 3 is formed after the first insulator 13 and the yoke column insulator 22 are injection molded. The first inductor coil 11 and the first magnetic core column 12 are fixed together by injection molding the first inductor 13 to form a first assembly 1, and the first insulator 13 is filled into the gap between the first inductor coil 11 and the first magnetic core column 12. The yoke column insulator 22 is injection molded on the yoke column 21 to form a yoke column assembly 2, and at the same time as the yoke column insulator 22 is molded, a first positioning structure 221 is molded. In this way, the first positioning structure 221 facilitates the assembly of the first inductor coil 11, the first insulator 13 and the yoke column 21. Similarly, the yoke column 21, the end yoke 4, the first magnetic core column 12 and the second magnetic core column 52 positioned together are fixed by the inductor insulator 3.

[0067] In one embodiment, the yoke column insulator 22 has a first positioning structure 221 for positioning the first inductor 11 (see Figure 9 ). The yoke column insulator 22 and the first insulator 13 are separately injection molded, which is beneficial to reduce the injection pressure of the injection molding process. Similarly, in one embodiment, please refer to Figure 9 The yoke column insulator 22 has a second positioning structure 222 for positioning the second inductor 51 .

[0068] In one embodiment, please refer to Figure 8 and Figure 9The first positioning structure 221 includes a first positioning groove 2211, through which the yoke column insulator 22 clamps the first inductor 11, and the bottom surface of the first positioning groove 2211 is in contact with the surface of the first inductor 11. Similarly, in one embodiment, the second positioning structure 222 includes a second positioning groove 2221, through which the yoke column insulator 22 clamps the second inductor 51. In some other embodiments, in addition to the positioning groove, the first positioning structure 221 may also include a positioning block. In this case, a positioning groove or positioning hole that is compatible with the positioning block may be formed on the first insulator 13.

[0069] In one embodiment, please refer to Figure 9 The yoke column insulator 22 is an injection molding cylinder, the yoke column 21 is flat, and the first positioning structure 221 and the second positioning structure 222 are located outside the cylinder wall of the injection molding cylinder.

[0070] Further, in one embodiment, please refer to Figure 4 、 Figure 5 and Figure 10 The inductor includes a pre-positioning member 10, which is connected to the first insulator 13 and the second insulator 53 and is used to pre-position the first insulator 13 and the second insulator 53. Before the insulator 3 of the inductor fixes the first magnetic core leg 12 and the second magnetic core leg 52, the pre-positioning member 10 pre-positions the first magnetic core leg 12 and the second magnetic core leg 52.

[0071] For details, please refer to Figure 4 and Figure 10 The pre-positioning member 10 is a positioning plate with a protrusion 101 on it. The first insulator 13 and the second insulator 53 are both provided with a positioning hole 102 for the protrusion 101 to be inserted into. After the protrusion 101 is inserted into the positioning hole 102, the positioning plate pre-positions the first insulator 13 and the second insulator 53 together, thereby facilitating the assembly of the yoke column 21, the first magnetic core column 12 and the second magnetic core column 52. Furthermore, there are two positioning plates, which are located at both ends of the extension direction of the first insulator 13. The positioning protrusion 101 is located on the opposite side of the two positioning plates. During installation, the protrusion 101 is inserted into the positioning hole 102 along the extension direction of the first magnetic core column 12.

[0072] Further, in one embodiment, please refer to Figure 1 、 Figure 2 、 Figure 5 and Figure 6The inductor lead 6 of the inductor includes a wiring conductive bar 61. In order to improve the stability of the wiring conductive bar 61, the wiring conductive bar 61 includes a first wiring conductive bar 611 connected to the first inductor coil 11, and the inductor insulator 3 includes a conductive bar injection-molded portion 321 injected onto the first wiring conductive bar 611. This can improve the strength of the first wiring conductive bar 611, making the first wiring conductive bar 611 less prone to shaking and less likely to be bent and deformed. In particular, for some special structures of the wiring conductive bar 61, for example, due to the requirements of the installation location, the first wiring conductive bar 611 needs to extend a long distance. In this case, the first wiring conductive bar 611 is fixed after injection molding using the inductor insulator 3, so that the first wiring conductive bar 611 has better stability. In one embodiment, the first wiring conductive bar 611 is also connected to the second inductor coil 51.

[0073] In one embodiment, please refer to Figures 1 to 12 , an inductor forming method comprises the following steps:

[0074] The first inductor 11 of the inductor is placed around the periphery of the first magnetic core column 12, and the first magnetic core column 12 and the first inductor 11 are fixed by injection molding a first insulator 13, and at least a portion of the first insulator 13 is filled into the gap between the first magnetic core column 12 and the first inductor 11 to prepare a first assembly 1.

[0075] The second inductor 51 of the inductor is placed around the second magnetic core column 52, and the second magnetic core column 52 and the second inductor 51 are fixed by injection molding a second insulator 53, and at least a portion of the second insulator 53 is filled into the gap between the second magnetic core column 52 and the second inductor 51 to prepare a second assembly 5.

[0076] A yoke column insulator 22 is injection-molded on the yoke column 21 of the inductor, and a first positioning structure 221 and a second positioning structure 222 are formed on the yoke column insulator 22 to prepare a yoke column assembly 2 .

[0077] The first assembly 1, the second assembly 5 and the yoke column assembly 2 are positioned and assembled, so that the first assembly 1 is positioned with the first positioning structure 221, and the second assembly 5 is positioned with the second positioning structure 222, and the first assembly 1 and the yoke column assembly 2 are fixed together by injection molding the inductor insulator 3.

[0078] When the inductor insulator 3 is injection-molded, the first assembly 1 , the second assembly 5 , and the yoke column assembly 2 are fixed together.

[0079] By injection molding the insulators in the inductor in batches, the first inductor coil 11 and the first magnetic core column 12 are pre-injected and fixed together. In this way, the injection molding pressure required for the first insulator 13 is less than the injection molding pressure of the entire inductor. The injection molding pressure on the first magnetic core column 12 is smaller and less likely to be damaged, thereby improving the yield of the inductor. Similarly, the injection molding pressure on the yoke column 21 is also smaller, and the first positioning structure 221 formed on the yoke column insulator 22 facilitates the assembly of the first magnetic core column 12 and the yoke column 21, which can improve the molding efficiency of the inductor. When the first magnetic core column 12, the second magnetic core column 52 and the yoke column 21 are fixed by the inductor insulator 3, since the first insulator 13 fixes the first magnetic core column 12 and the first inductor coil 11, the first magnetic core column 12 and the first inductor coil 11 have a higher overall compressive strength, can withstand a larger injection molding pressure, are not easily damaged by the injection molding pressure, and the molded inductor has a higher yield.

[0080] In one embodiment, the injection molding pressure of the inductor insulator 3 is greater than the injection molding pressure of the first insulator 13, greater than the injection molding pressure of the second insulator 53, and greater than the injection molding pressure of the yoke column insulator 22. In some other embodiments, the injection molding pressures of different insulators can be set as needed. For example, the injection molding pressure of the inductor insulator 3 can also be less than or equal to the injection molding pressure of the first insulator 13. The injection molding pressure of the inductor insulator 3 can also be less than or equal to the injection molding pressure of the second insulator 53. The injection molding pressure of the inductor insulator 3 can also be less than or equal to the injection molding pressure of the yoke column insulator 22.

[0081] For details, please refer to Figures 1 to 11 , the detailed steps of the inductor forming method in one embodiment are as follows:

[0082] The first inductor 11 and the first magnetic core 12 are positioned and assembled in an injection mold, and then injection molded to form a first assembly 1. The structure of the first assembly 1 has been described in detail above and will not be repeated here. The second assembly 5 is formed in the same way.

[0083] The yoke column 21 is positioned and placed into an injection mold, and a yoke column insulator 22 is injection-molded on the yoke column 21 to form a yoke column assembly 2 .

[0084] After installing the wiring conductive bar 61, the first assembly 1, the second assembly 5, the yoke column assembly 2, the end yoke 4, and the insert are positioned and placed into the injection mold for injection molding. The injection-molded inductor insulator 3 fixes the above components together and covers the wiring conductive bar 61 to form the main body of the inductor. Then, the other inductor leads 6 are installed.

[0085] In one embodiment, the inductor is a high-power inductor that can be used in automobiles, such as in high-power voltage conversion circuits. Specifically, in one embodiment, the inductor is a boost inductor connected in parallel.

[0086] In one embodiment, the magnetic integrated inductor adopts an integrated injection molding process, has high overall dimensional accuracy, and is suitable for a heat dissipation process in which a thermally conductive silicone gasket is installed at the bottom of the coil. Compared with traditional potted inductors, it has a smaller size, lighter weight, and better heat dissipation performance.

[0087] In one embodiment, based on the principle of heat dissipation of the bottom coil of the inductor, when the size of the inductor in the width direction (i.e., the first direction) is limited, the yoke column is designed to be connected to the end yoke at the top of the coil, saving width space for the coil, increasing the heat dissipation area of ​​the coil, and improving the heat dissipation effect.

[0088] In one embodiment, the coils are constructed from thin, flat metal conductors, which are relatively thin, thus reducing the amount of metal conductor used. As the metal conductors are thinner, the lengths of the first and second magnetic core legs are also reduced, thereby reducing the amount of magnetic core used and further reducing raw material costs. In one embodiment, the first and second inductor coils are wound in the same manner, either in a forward or reverse winding pattern.

[0089] The above examples are used to illustrate the present invention, which are only used to help understand the present invention and are not intended to limit the present invention. For those skilled in the art of the present invention, some simple deductions, modifications or substitutions can be made based on the concept of the present invention.

Claims

1. An inductor, characterized in that: The invention comprises a first inductor coil, a second inductor coil, a first magnetic core column, a second magnetic core column, a magnetic yoke column and an end magnetic yoke; the first inductor coil is sleeved around the outer periphery of the first magnetic core column and a first insulator is filled between the two, the second inductor coil is sleeved around the outer periphery of the second magnetic core column and a second insulator is filled between the two, the end magnetic yoke is located at the end of the magnetic yoke column, and the magnetic path between the magnetic yoke column and the first magnetic core column and the magnetic path between the magnetic yoke column and the second magnetic core column are both conducted through the end magnetic yoke; The first magnetic core column and the second magnetic core column are arranged in a first direction, the first magnetic core column, the second magnetic core column and the yoke column all extend along the second direction, and the first direction is perpendicular to the second direction; the first direction and the second direction are both perpendicular to a third direction, and the yoke column is arranged on one side of the first magnetic core column in the third direction.

2. The inductor according to claim 1, wherein The end of the first magnetic core column, the end of the second magnetic core column and the end of the magnetic yoke column are all magnetically conductive with the end magnetic yoke; the end magnetic yoke includes a first magnetic core column conductive surface that is magnetically conductive with the first magnetic core column, a second magnetic core column conductive surface that is magnetically conductive with the second magnetic core column and a yoke column conductive surface that is magnetically conductive with the magnetic yoke column, the first magnetic core column conductive surface is perpendicular to the magnetic yoke column conductive surface, and the first magnetic core column conductive surface and the second magnetic core column conductive surface are both on one side of the end magnetic yoke in the second direction.

3. The inductor according to claim 1 or 2, characterized in that: The inductor includes a yoke column insulator, which is covered on the yoke column. The side of the first inductor coil facing the yoke column and the side of the second inductor coil facing the yoke column are both in contact with the yoke column insulator.

4. The inductor according to claim 3, wherein: The side surface of the first inductor coil facing away from the yoke column and the side surface of the second inductor coil facing away from the yoke column are both exposed heat dissipation surfaces, and the heat dissipation surfaces are used to fit with the thermal pad for heat dissipation.

5. The inductor according to claim 4, wherein: The inductor includes an inductor insulator, which fixes the yoke column, the end yoke, the first magnetic core column and the second magnetic core column. The inductor insulator includes an extrusion protrusion protruding toward the third direction. The extrusion protrusion is arranged on the periphery of the heat dissipation surface to squeeze the thermal pad to cause the thermal pad to be recessed.

6. The inductor according to claim 1 or 2, characterized in that: The yoke column is in a flat plate shape.

7. The inductor according to claim 1 or 2, wherein: The yoke column includes a first column and a second column, the first column and the second column are arranged along a first direction, the first column and the second column are in contact with each other, or the first column and the second column are arranged at intervals along the first direction and form a column gap, the inductor includes an inductor lead, at least one of the inductor leads and / or the terminal of the first inductor coil and / or the terminal of the second inductor coil passes through the column gap.

8. The inductor according to claim 1 or 2, wherein: The inductor is a magnetically integrated interleaved parallel inductor, and the first inductor coil and the second inductor coil are connected in parallel.

9. The inductor according to claim 1 or 2, characterized in that: The inductor includes a first inductor insulator and a second inductor insulator, wherein the first inductor insulator and the second inductor insulator are arranged at intervals in the extension direction of the yoke column, at least one end yoke is a first yoke magnetically connected to one end of the yoke column, and at least one end yoke is a second yoke magnetically connected to the other end of the yoke column; the first inductor insulator fixes one end of the yoke column to the first yoke, and the second inductor insulator fixes the other end of the yoke column to the second yoke.

10. The inductor according to claim 9, wherein: The first inductor insulator includes a surface portion covering the outer surface of the first magnetic yoke and an inner portion located on the side of the first magnetic yoke facing the first magnetic core column, and the inner portion is connected to the surface portion; in the extension direction of the first magnetic core column, at least a portion of the inner portion is located between the first insulator and the end magnetic yoke.

Images