Double inductor suitable for high-density PCB
By optimizing the core and coil structure of the dual inductor and combining it with hot pressing and electroplating processes, the problems of large space occupation and unstable performance of dual inductor devices in high-density PCBs were solved, the stability and performance of the inductor devices were improved, and the development of related hardware equipment was promoted.
Patent Information
- Application Number
- CN202422584892.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-25
- Publication Date
- 2025-09-23
- Estimated Expiration
- 2034-10-25
AI Technical Summary
With the miniaturization and high-density assembly of electronic products, dual-inductor devices are difficult to ensure independent operation and low mutual interference. They occupy a large space and have unstable performance, which affects the development of circuit design and hardware equipment.
A pre-formed double-T core, a cap core, and two identical coils are combined. By optimizing the core shape and coil structure, combined with hot pressing and electroplating processes, a stable inductor device is formed, which reduces space occupancy and improves performance.
It achieves the stability and performance improvement of inductive devices in high-density PCBs, reduces space occupancy and interference impact, and promotes the development of hardware performance such as artificial intelligence (AI) servers, data centers, and autonomous driving.
Smart Images
Figure CN223378003U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to an inductor device, in particular to a dual-inductor device with low space occupation and improved performance, 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] Inductors are widely used in DC-DC converter buck (Buck) circuits and have a crucial impact on their conversion efficiency, constraining the development of big data processing hardware to a certain extent. Currently, designs and products integrating dual inductors into a single component are widely available. However, due to the variability of various application circuit designs, it is often desired that each integrated inductor can operate independently to achieve the required function with minimal cross-interference. Furthermore, with the demand for miniaturization of electronic products, as an indispensable component for the power supply, in addition to the pursuit of high performance of the inductor, the dual inductor's form factor and footprint have become key considerations for circuit designers. Inductor products require breakthroughs in all aspects, including stable performance parameters, durability, and installation compatibility. Summary of the Invention
[0004] The purpose of this utility model is to propose a dual inductor suitable for high-density PCBs, which is committed to improving the performance of inductor devices and their adaptability to various application scenarios.
[0005] The technical solution for achieving the above-mentioned object of the present invention is: a dual inductor suitable for high-density PCBs, which is formed by combining a preformed double-T magnetic core, a cap magnetic core and two identical coils, wherein the double-T magnetic core is provided with a bottom plate and two upright columns with their top surfaces extending upward as an integral part, the coils are wound from metal wire into a hollow spiral shape and are sleeved one-by-one on the upright columns, the two ends of the coils extend in the same direction and are continuously bent to form clips, the clips wrap around the bottom plate and secure the coils to form an assembly, the cap magnetic core is fully enclosed in the assembly in a hot pressing mold and hot-pressed into an integral body, and the exposed portions of the corresponding clips are provided as electrode pads.
[0006] Furthermore, the four corners of the bottom plate are inwardly shrunk to form notches, and the clips are inserted into the notches one by one and clamp the bottom plate. The size of the notches corresponds to the cross section of the metal wire, so that the clips can be retracted into the four sides of the bottom plate.
[0007] Furthermore, the height of the column is greater than the axial length of the coil, and the top end of the column is engaged with the inner wall of the cap-type magnetic core.
[0008] Furthermore, the double-T magnetic core and the cap-type magnetic core are both cold-pressed bodies made of powder materials based on customized molds.
[0009] Furthermore, the metal wire of the coil is a round copper wire, and the ends extending in the same direction are flattened and bent into clips.
[0010] Furthermore, the metal wire of the coil is a flat copper wire, and the ends extending in the same direction are parallel.
[0011] Furthermore, the inner bottom surface of the hot pressing mold is provided with cross-shaped ribs, so that the areas where each clip is located are independently separated, and the surface of the hot-pressed dual-inductor semi-finished product is provided with a paint layer, and the electrode pads are partially obtained by paint stripping and electroplating.
[0012] Compared with existing technologies, the advantages of this dual inductor are as follows: by optimizing the shape and assembly structure of the prefabricated magnetic core and the shape of the supporting coil, product assembly stability and manufacturing consistency are ensured, helping to reduce the space occupied by the inductor components in high-density PCBs and the impact on surrounding interference. At the same time, the two sets of multi-turn coils enhance the performance of the inductor device, reducing the mutual coupling coefficient k within the inductor device to less than 0.1. This further improves the circuit operating environment and promotes the development of hardware performance in application scenarios such as artificial intelligence (AI) servers, data centers, autonomous driving, and smart city transportation. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Figure 1 It is a schematic diagram of the explosion structure of the dual inductor of the utility model.
[0014] Figure 2 It is a schematic diagram of the appearance evolution of the assembly and manufacturing of the utility model. DETAILED DESCRIPTION
[0015] In order to enable people 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.
[0016] This utility model proposes a dual inductor suitable for high-density PCB. Figure 1 and Figure 2As shown, the basic structure of the dual inductor is formed by combining a pre-formed double-T magnetic core 1, a cap-type magnetic core 3, and two identical coils 2. When the functional components are unfolded, the double-T magnetic core 1 is provided with a base plate 11 and two columns 12 integrally extended upward from its top surface. Its shape can be cylindrical or square. Each coil 2 is wound from a metal wire into a hollow spiral and is suitable for being sleeved one-by-one on the column 12. Due to the spiral winding, the coil has a free end on each of the bottom and top sides and extends in the same direction. When reaching a vertical plane parallel to the central axis, it simultaneously bends downward for a distance. Obviously, the free end on the top side bends downward for a longer distance, and the two free ends are then bent at the same horizontal position in the opposite direction of the previous extension direction and extend a distance (beyond the radius of the hollow spiral) to form a clip. The clip can wrap around the base plate and fix the coil into an assembly. Finally, the cap core 3 itself is formed into a thin-walled rectangular container with one side open. After the aforementioned components are preloaded into the hot-pressing mold, the cap core is also placed into the mold and flipped upside down to fully enclose the components. Finally, the entire assembly is hot-pressed and packaged. Essentially, as a foundation for connecting the inductor to the PCB, after hot-pressing and painting, the exposed portions of the corresponding clips are stripped and electroplated to form electrode pads.
[0017] Based on this technical solution overview, the detailed features of each functional component include: Figure 1 As shown, the four corners of the bottom plate 11 of the double-T magnetic core 1 are inwardly shrunk to form notches 111, so that the projection shape of the bottom plate is cross-shaped. Therefore, when the coil and the magnetic core are assembled, the individual clips of the coil will be inserted into the notches one by one and clamp the bottom plate, and no additional protrusions will be formed, which is conducive to reducing the overall length of the inductor. To this end, the size of the notch 111 needs to correspond to the cross-section of the metal wire, so that the clips can be retracted into the four sides of the bottom plate. On the other hand, the height of the above-mentioned column 12 is preferably set to be slightly larger than the axial length of the coil, so that in the mold before hot pressing, the top of the column 12 can contact the inner wall of the cover-type magnetic core 3.
[0018] The metal wire of the coil 2 is round copper wire or flat copper wire, and the preferred embodiment shown in the figure uses flat copper wire. Based on the winding and extending bending shape characteristics of the above-mentioned coils, the two coils used in the dual inductor are wound and bent in a mirror-image manner. That is, the free ends on the bottom side face forward, and the free ends on the top side face backward. Of course, the two coils can also be wound and bent in a consistent manner, which is conducive to improving the efficiency of large-scale manufacturing, and after the two coils are assembled, the free ends on the bottom side and the top side will be staggered one after the other. Of course, the metal wire of the coil can also be round copper wire. In this way, the ends extending in the same direction after the winding is completed can be flattened to facilitate subsequent bending and forming of the clip.
[0019] Based on the prefabrication and forming of the coil described above, it is important to understand that the coil is formed as it is assembled. That is, when it is sleeved onto the column, the two free ends have not completed the entire bending operation. Only after it is in place and contacts the surface of the base plate can the final bending be performed and the base plate be clamped.
[0020] As a further optimization, the inner bottom surface of the above-mentioned hot pressing mold is provided with cross-shaped ribs, so that the inductor components after hot pressing are independently separated from the areas where each clip is located, which provides convenience for paint stripping and electroplating in subsequent processes, and also enables the dual inductors to quickly release the heat generated during actual operation.
[0021] like Figure 2 The complete manufacturing process of the dual inductor is shown below. First, the double-T core, cap core, and coils are prefabricated and the quantities are matched according to the requirements. Then, the two coils are connected one by one to the column of the double-T core, so that the downward-facing free ends of each coil fall into the notch for initial positioning. Then, all free ends are bent closely to the bottom surface of the base plate to achieve the clamping function. Figure 2 Arrow A is shown. The assembly is then completely covered with a cover core and transferred into a hot pressing mold. Figure 2 Arrow B is shown. It is packaged into one piece under a temperature of 100-200℃ and a pressure of 4-10Tons / cm². The molding time is usually between 30-180 seconds, which can be adjusted according to the actual situation. After the product is demoulded, it is baked at a temperature of 100-180℃ for a period of time to completely solidify and set. Figure 2 Arrow C is shown. The surface of the semi-finished inductor is then fully sprayed with paint, and the location of the coil clip is laser stripped. Figure 2 Arrow D is shown. Finally, the exposed copper surface is electroplated to generate the electrode pads with clear spacing at the bottom of the device. Figure 2 As shown by arrow E.
[0022] Both the double-T core and cap core are assembled from powder materials and custom molds using a cold-pressing process. The core powder can be a mixture of one or more of the following: Fe-based, FeSi, FeSiCr, FeSiAl, FeNi, amorphous, or nanocrystalline. Epoxy, silicone, or acrylic resins are added, mixed, and then injected into a prefabricated mold designed to fit the device's shape. The molding pressure range is 6-10 tons / cm².
[0023] From the above detailed description of the preferred embodiment of the dual inductor for high-density PCBs, it can be seen that compared with the existing technology, it has substantial characteristics and progress. Its technical effects are manifested as follows: by optimizing the shape and assembly structure of the prefabricated magnetic core and the shape of the supporting coil, product assembly stability and manufacturing consistency are guaranteed, which helps to reduce the space occupied by the inductor components in high-density PCBs and the interference effect on the surrounding area. At the same time, the two sets of multi-turn coils improve the performance of the inductor device, making the mutual coupling coefficient k within the inductor device less than 0.1. This further improves the operating environment of the circuit and promotes the development of hardware performance in application scenarios such as artificial intelligence (AI) servers / data centers / autonomous driving, and smart city transportation.
[0024] 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 dual inductor suitable for high-density PCBs, characterized by: The dual inductor is formed by combining a preformed double-T magnetic core, a cap magnetic core and two identical coils. The double-T magnetic core is provided with a bottom plate and two columns with the top surface extending upward as an integral part. The coils are wound into a hollow spiral shape by metal wire and are sleeved on the columns one by one. The two ends of the coils extend in the same direction and are continuously bent to form clips. The clips wrap around the bottom plate and fix the coils to form an assembly. The cap magnetic core is fully wrapped in the assembly in a hot pressing mold and hot-pressed into an integral body, and the exposed parts of the corresponding clips are set as electrode pads.
2. The dual inductor suitable for high-density PCB according to claim 1, characterized in that: The four corners of the bottom plate are inwardly shrunk to form notches, and the clips are inserted into the notches one by one and clamp the bottom plate. The size of the notches corresponds to the cross section of the metal wire, so that the clips can be retracted into the four sides of the bottom plate.
3. The dual inductor suitable for high-density PCB according to claim 1, characterized in that: The height of the column is greater than the axial length of the coil, and the top of the column is connected to the inner wall of the cap-type magnetic core.
4. The dual inductor suitable for high-density PCB according to claim 1, characterized in that: The double-T magnetic core and the cap-type magnetic core are both cold-pressed bodies made of powder materials based on customized molds.
5. The dual inductor suitable for high-density PCB according to claim 1, characterized in that: The metal wire material of the coil is a round copper wire, and the ends extending in the same direction are flattened and bent into clips.
6. The dual inductor suitable for high-density PCB according to claim 1, characterized in that: The metal wires of the coils are flat copper wires, and the ends extending in the same direction are parallel.
7. The dual inductor suitable for high-density PCB according to claim 1, characterized in that: The inner bottom surface of the hot pressing mold is provided with cross-shaped ribs, so that the areas where each clip is located are independently separated. The surface of the hot-pressed packaged dual-inductor semi-finished product is provided with a paint layer, and the electrode pads are partially obtained by paint stripping and electroplating.