Multi-group integrated TLVR inductor

Abstract

The utility model discloses a multi-group integrated TLVR inductor, which is formed by combining a pre-formed primary magnetic core, a pre-formed secondary magnetic core, a pre-formed primary coil and a pre-formed secondary coil, the top surface of the primary magnetic core is provided with more than two parallel and spaced first accommodating grooves, and one end of each first accommodating groove is bent downwards and extends to the bottom surface of the primary magnetic core; more than two parallel and spaced second accommodating grooves are formed in the bottom surface of the secondary magnetic core, and the two ends of each second accommodating groove are upward and relatively continuously bent and extend; the primary coil is formed into a Z shape at a time and located in the first containing groove, the secondary coil is formed into a C shape at a second time and located in the second containing groove to wrap the second containing groove, two-stage magnetic cores loaded with the coils are spliced in an edging mode and packaged into a whole in a hot pressing mode, and exposed parts corresponding to the two ends of each coil are provided with electrode bonding pads. According to the inductor, the occupied space is reduced, the interference influence on the periphery is reduced, meanwhile, the performance of an inductor device is improved, the coupling coefficient in each group of two coils is larger than 0.93, and the coupling coefficient between different groups of coils is smaller than 0.1.

Description

Technical Field

[0001] The utility model relates to an inductor device, in particular to an inductor device with multiple integrations and improved insulation performance between two-level coils, 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 an emerging VR (Voltage Regulator) power supply architecture. The biggest difference between it and traditional DC-to-DC buck and DC (direct current) architectures is that the traditional single-winding ordinary inductor is improved to a transformer-like TLVR inductor with two windings. Ordinary inductors have only one set of windings and two pins, while TLVR inductors have two sets of mutually coupled windings and four pins. There is a significant difference in their structural form.

[0004] When designing TLVR inductors, the industry is currently focusing on not only the coupling efficiency between the two coils, but also the number of components and the space occupied within high-density PCBs. Therefore, the integration of TLVR inductors within limited space has become a technological gap that needs to be filled. Summary of the Invention

[0005] The purpose of this utility model is to propose a multi-group integrated TLVR inductor, which is committed to improving the performance of inductor devices and optimizing the component space occupied in high-density PCBs.

[0006] The technical solution of the present invention to achieve the above-mentioned purpose is: a multi-group integrated TLVR inductor, which is formed by combining a pre-formed primary magnetic core, a secondary magnetic core, a primary coil, and a secondary coil. The top surface of the primary magnetic core is provided with two or more parallel and spaced first grooves, and one end of each first groove is bent downward and extends to the bottom surface of the primary magnetic core; the bottom surface of the secondary magnetic core is provided with two or more parallel and spaced second grooves, and the two ends of each second groove are bent upward and extended to the top surface of the secondary coil and bent and extended relative to each other; the primary coil is formed into a Z shape at one time and is placed in the first groove, and the secondary coil is formed into a C shape at a second time and is placed and wrapped around the second groove. The primary magnetic core and secondary magnetic core each carrying a coil are spliced ​​together and hot-pressed into a whole, and the exposed parts corresponding to the two ends of each coil are set as electrode pads.

[0007] Furthermore, the depth of the first containing groove in the primary magnetic core is the same as the thickness of the primary coil, and the width of the first containing groove is adapted to the width of the primary coil.

[0008] Furthermore, four first receiving grooves are provided in the primary magnetic core, and the notches formed by two adjacent first receiving grooves are bent downward and extended in opposite directions. The hanging end of the primary coil falls in the notch, and the upright end of the primary coil protrudes from the top surface of the primary magnetic core.

[0009] Furthermore, the depth of the second containing groove in the secondary magnetic core is the same as the thickness of the secondary coil, and the width of the second containing groove is adapted to the width of the secondary coil.

[0010] Furthermore, four second containing grooves are provided in the secondary magnetic core, the notch ribs formed at both ends of each second containing groove have different depths, and the notch ribs formed on the same side of two adjacent second containing grooves have staggered depths.

[0011] Furthermore, the primary magnetic core and the secondary magnetic core are both formed by hot pressing powder materials based on customized molds.

[0012] Furthermore, the primary coil is a multiplexed component formed by cutting and bending a flat copper strip, and the secondary coil is another multiplexed component formed by cutting and bending a flat enameled wire.

[0013] Furthermore, when the two magnetic cores are aligned and spliced ​​together, the raised end of the primary coil is compatible with the local depression of the secondary coil and wraps a portion of the secondary coil.

[0014] Compared with the existing technology, the advantages of the multi-group integrated TLVR inductor of the present invention are as follows: by optimizing the prefabricated shape and assembly structure of the two-stage magnetic core and coil, on the one hand, 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 impact on the surrounding environment; on the other hand, each group of coils and each group of two-stage coils are reliably isolated, improving the withstand voltage between the two-stage coils and device performance, while ensuring that the mutual coupling coefficient of each group of two coils is greater than 0.93, and the mutual coupling coefficient between different groups of coils is 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. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 1 is a close-up structural diagram of the primary magnetic core in a preferred embodiment of the TLVR inductor of the present invention.

[0016] Figure 2 1 is a close-up structural diagram of the primary coil in a preferred embodiment of the TLVR inductor of the present invention.

[0017] Figure 3 1 is a close-up structural diagram of the secondary magnetic core in a preferred embodiment of the TLVR inductor of the present invention.

[0018] Figure 4 1 is a close-up structural diagram of the secondary coil in the preferred embodiment of the TLVR inductor of the present invention.

[0019] Figure 5 This is a schematic diagram of the appearance evolution of the assembly and manufacturing of the preferred embodiment of the TLVR inductor of the present invention. DETAILED DESCRIPTION

[0020] 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.

[0021] This utility model proposes a multi-group integrated TLVR inductor, which is dedicated to improving the performance of inductor devices and optimizing the space occupied by components in high-density PCBs. Figures 1 to 5As shown, the basic structure of the inductor is assembled from a pre-formed primary magnetic core 21, a secondary magnetic core 22, a primary coil 11, and a secondary coil 12, and then undergoes a series of processes such as hot pressing, painting, paint stripping, and electroplating. From the overview of the functional components, the top surface 21a of the primary magnetic core 21 is provided with two or more parallel and spaced first grooves 211, and one end of each first groove 211 is bent downward and extended to the bottom surface 21b of the primary magnetic core, in preparation for assembling and positioning the primary coil. The bottom surface 22b of the secondary magnetic core 22 is provided with two or more parallel and spaced second grooves 221, and the two ends of each second groove 221 are bent upward and extended to the top surface 22a of the secondary coil and bent relative to each other, for the assembly and positioning of the secondary coil. On the other hand, the primary coil is made of flat copper strip, which is cut into sections according to the design specifications of the inductor and then formed into a Z shape through continuous bending. The main body of the primary coil 11 is flatly positioned in the first receiving groove, with one end of the primary coil 11 being bent vertically upward to form an upright end 112, and the other end being bent vertically downward to form a hanging end 111. The secondary coil 12 is made of flat enameled wire, which is also cut into sections according to the design specifications of the inductor. Compared with the primary coil 11, its main body is also flatly positioned in the second receiving groove, but the difference is that one end of the secondary coil is continuously bent to form a first hook portion 121 with a right-angle inward shape, and the other end is kept flat as an extended portion 122a before being assembled with the secondary core, and is continuously bent to form a second hook portion 122b with a right-angle inward shape after being assembled with the secondary core (such as Figure 5 As shown in the figure, the secondary coil is then bent twice to form a C-shaped enclosure around the second slot. After pre-assembly of the primary and secondary cores and coils, the two semi-finished parts are aligned and then hot-pressed together using specialized packaging equipment and custom molds. As the foundation for connecting the inductor to the PCB, after hot-pressing and painting, the exposed portions of each coil's ends are stripped and electroplated to form electrode pads.

[0022] Due to the consideration of multiple integrated design, the number of the above coils and slots is plural. Therefore, the two-stage coils can be prefabricated and reused in batches.

[0023] Based on the overview of this technical solution and the diagram of the preferred embodiment, the detailed features of each functional component of the inductor also include: Figure 1As shown, the primary magnetic core 21 is a rectangular block as a whole. After being pre-configured in a customized shape, most of its bottom surface is flat, and the top surface is provided with four parallel and spaced first receiving grooves 211. These first receiving grooves are adapted to the above-mentioned primary coil in terms of specifications and dimensions; specifically, the depth is the same as the thickness of the primary coil, so as to ensure that the primary coil is flush with the top surface of the primary magnetic core after assembly without any protruding parts, and the width is sufficient to ensure that the primary coil assembled therein cannot swing freely and obviously. In particular, the notch grooves 212 formed by the downward bending and extension of two adjacent first receiving grooves face opposite directions. That is, the notch groove formed by the first receiving groove at the proximal end of the figure is on the right, and the notch groove formed by the adjacent first receiving groove is on the left, and so on. When the corresponding Z-shaped primary coil is assembled facing the primary magnetic core, the overhanging end on one side of each primary coil falls into the notch groove, and the upright end on the other side protrudes from the top surface of the primary magnetic core. This design facilitates the subsequent assembly and splicing of the secondary magnetic core, and it can be understood that the primary coil has one docking terminal facing upward and one docking terminal facing downward when the inductor is connected to the PCB.

[0024] For example Figure 3 As shown, the secondary magnetic core 22 is also a rectangular block as a whole, which has been thinned compared to the primary magnetic core. After customized shape pre-construction, most of its top surface is flat, while the bottom surface is provided with four parallel and spaced second grooves 221. The specifications and dimensions of these second grooves are also adapted to the secondary coil; specifically, the depth is the same as the thickness of the secondary coil, so as to ensure that the secondary coil is flush with the bottom surface of the secondary magnetic core after assembly without any protruding parts, and the width is sufficient to ensure that the secondary coil assembled therein cannot swing significantly freely. In particular, different from the notch groove formed by the first groove, both ends of the second groove here are bent upward and extended to the opposite side, forming a notch rib suitable for wrapping the secondary coil. Moreover, one side of each second groove is formed as a shallow notch rib 222a, and the other side is formed as a deep notch rib 222b, and the notch ribs formed on the same side of two adjacent second grooves are staggered in depth. That is, the second receiving groove at the proximal end is formed with a shallow notch rib on the right side and a deep notch rib on the left side, while the adjacent second receiving groove is formed with a deep notch rib on the right side and a shallow notch rib on the left side, and so on. Figure 5 As shown, after the secondary core and secondary coil are assembled, concave spaces still exist on either side of the secondary core, corresponding to the deep notches and ribs. Therefore, when the two cores are aligned, the raised ends of the primary coil can be aligned and compatible within these concave spaces of the secondary core, partially enclosing the secondary coil. It should be understood that all the mating terminals of the secondary coil face upward when the inductor is connected to the PCB.

[0025] like Figure 5As shown, the complete manufacturing process of these multiple integrated TLVR inductors is as follows: First, the primary magnetic core, secondary magnetic core, primary coil, and secondary coil are prefabricated, with the desired number of coils. Then, step S1 is performed to pre-assemble the primary coil 11 with the primary magnetic core 21, resulting in a semi-finished assembly B. Note that the overhanging end of each primary coil is positioned within the notched slot of the primary magnetic core. Synchronously or asynchronously, step S12a is performed to pre-assemble the secondary coil 12 with the secondary magnetic core 22, with the first hook portion 121 wrapping around the shallow-notched rib 222a. Then, step S12b is performed to continuously bend the extended portion 122a of the secondary coil to wrap around the deep-notched rib 222b and form the second hook portion 122b, resulting in a semi-finished assembly A. Next, step S2 is performed to align the two semi-finished assemblies, and then step S3 is performed to heat-press the molded body C at a molding pressure of 4-10 tons / cm² (a common technique in the art, and detailed description omitted). After cooling, the hot-pressed packaged body undergoes a spray-painting process in step S4, coating its entire surface with an insulating paint film 3. Then, in step S5, a partial paint stripping process is performed to form partially exposed but disconnected conductor contact pads 13 at both ends of the primary and secondary coils. Finally, in step S6, electroplating is performed to form the electrode pads 4 distributed on the top and bottom surfaces of the TLVR inductor.

[0026] Both the primary and secondary cores are assembled from powder materials and custom molds using a hot-pressing process. The core powder can be a mixture of one or more of the following: Fe-based, 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 temperature range is 100-200°C, and the molding pressure range is 4-12 tons / cm².

[0027] From the above detailed description of the preferred embodiment of the multi-group integrated TLVR inductor of the utility model, it can be seen that compared with the existing technology, its technical effects are as follows: by optimizing the prefabricated shape and assembly structure of the two-stage magnetic core and coil, on the one hand, the product assembly stability and manufacturing consistency are guaranteed, which helps to reduce the space occupied by the components of the inductor in high-density PCB and the interference effect on the surrounding area; on the other hand, each group of coils and each group of two-stage coils are reliably isolated, effectively improving the withstand voltage between the two-stage coils and the device performance. Ansys Maxwell simulation shows that in the multi-group integrated TLVR inductor, the mutual coupling coefficient between the primary coil and the secondary coil of a single group is greater than 0.93, while the mutual coupling coefficient between different groups of coils is less than 0.1. It 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, smart city transportation, etc.

[0028] 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 multi-group integrated TLVR inductor, characterized by: The inductor is formed by a combination of pre-formed primary magnetic core, secondary magnetic core, primary coil and secondary coil. The top surface of the primary magnetic core is provided with two or more parallel and spaced first grooves, and one end of each first groove is bent downward and extended to the bottom surface of the primary magnetic core; the bottom surface of the secondary magnetic core is provided with two or more parallel and spaced second grooves, and the two ends of each second groove are bent upward and extended to the top surface of the secondary coil and bent and extended relative to each other; the primary coil is formed into a Z shape and placed in the first groove, and the secondary coil is formed into a C shape and placed and wrapped in the second groove. The primary magnetic core and secondary magnetic core respectively carrying the coils are spliced ​​together and hot-pressed into one body, and the exposed parts corresponding to the two ends of each coil are set as electrode pads.

2. The multiple integrated TLVR inductors according to claim 1, wherein: The depth of the first containing groove in the primary magnetic core is the same as the thickness of the primary coil, and the width of the first containing groove is adapted to the width of the primary coil.

3. The multiple integrated TLVR inductors according to claim 1, wherein: Four first receiving grooves are provided in the primary magnetic core, and the notches formed by bending and extending two adjacent first receiving grooves downward are in opposite directions. The hanging end of the primary coil falls into the notch, and the upright end of the primary coil protrudes from the top surface of the primary magnetic core.

4. The multiple integrated TLVR inductors according to claim 1, wherein: The depth of the second containing groove in the secondary magnetic core is the same as the thickness of the secondary coil, and the width of the second containing groove is adapted to the width of the secondary coil.

5. The multiple integrated TLVR inductors according to claim 1, wherein: Four second containing grooves are provided in the secondary magnetic core. The notch ribs formed at both ends of each second containing groove have different depths, and the notch ribs formed on the same side of two adjacent second containing grooves have staggered depths.

6. The multiple integrated TLVR inductors according to claim 1, wherein: The primary magnetic core and the secondary magnetic core are both formed by hot pressing powder materials based on customized molds.

7. The multiple integrated TLVR inductors according to claim 1, wherein: The primary coil is a multiplexed accessory formed by cutting and bending a flat copper strip, and the secondary coil is another multiplexed accessory formed by cutting and bending a flat enameled wire.

8. The multiple integrated TLVR inductors according to claim 1, wherein: When the two magnetic cores are aligned and spliced ​​together, the raised end of the primary coil is compatible with the local depression of the secondary coil and wraps a portion of the secondary coil.

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