Integrally-formed row type uncoupled inductor

Abstract

The utility model discloses an integrally formed row type uncoupled inductor, which is formed by combining a pre-formed cup type magnetic core, an I-strip magnetic core and a plurality of U-shaped coils, the cup type magnetic core is a rectangular block container with an open top surface, more than three spaced accommodating grooves are arranged in a cavity of the cup type magnetic core, and all the accommodating grooves are parallel to the short side wall of the cup type magnetic core; positioning notches are formed in the positions, on the long side wall of the cup type magnetic core, of the two ends of each containing groove, the U-shaped coils are formed by bending copper strips, the two ends of each U-shaped coil are in lap joint with the positioning notches, the I-shaped magnetic cores are filled in a cavity of the cup type magnetic core, the middles of all the U-shaped coils are pressed to the corresponding containing grooves, and the two magnetic cores are packaged into a whole in a hot pressing mode. And an electrode bonding pad is arranged corresponding to the end part of each U-shaped coil. According to the row type uncoupled inductor, the occupied space of the inductor in components in a high-density PCB is reduced, meanwhile, the performance of an inductor device is improved, the mutual coupling coefficient k in the inductor device is smaller than 0.1, and hardware performance development under multiple application scenes can be promoted.

Description

Technical Field

[0001] The utility model relates to an inductor device, in particular to a row-type uncoupled inductor for optimizing the space occupied by inductor elements and improving device performance in a high-density PCB, 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 two inductors into a single component are widely available. However, due to the variability of application circuit designs, the demand for more single integrated inductors is increasing. Furthermore, it is often desired that each integrated inductor operate independently to achieve its desired function with minimal cross-interference, placing higher demands on the inductor's structural design. Summary of the Invention

[0004] The purpose of the utility model is to provide an integrally formed row-type uncoupled inductor, which is dedicated to improving the integrated scale and performance of inductor devices and reducing the coupling coefficient.

[0005] The technical solution for achieving the above-mentioned purpose of the present invention is: an integrally formed row-type uncoupled inductor, characterized in that: the inductor is formed by combining a preformed cup-type magnetic core, I magnetic core and a plurality of U-shaped coils, wherein the cup-type magnetic core is a rectangular container with an open top surface, and the cavity of the cup-type magnetic core is provided with three or more spaced-apart accommodating grooves, and all the accommodating grooves are parallel to the short side walls of the cup-type magnetic core, and the two ends of each accommodating groove are set as positioning notches on the long side walls of the cup-type magnetic core, the U-shaped coil is formed by bending a copper strip and the two ends are overlapped at the positioning notches, the I magnetic core is filled in the cavity of the cup-type magnetic core and the middle parts of all the U-shaped coils are pressed into the corresponding accommodating grooves, the two parts of the magnetic core are hot-pressed and packaged into one, and the ends of the corresponding U-shaped coils are set as electrode pads.

[0006] Furthermore, the cup-type magnetic core is provided with an isolation boss with increased wall thickness between two adjacent accommodating grooves, and the inner wall spacing of the isolation boss matches that of one magnetic core to be installed therein.

[0007] Furthermore, the height of the I magnetic core is sufficient to be lower than the surface of the long side wall when the I magnetic core is loaded into the cup-shaped magnetic core cavity, thereby forming a heat dissipation channel at the bottom of the inductor.

[0008] Furthermore, the cup-type magnetic core and the I-bar magnetic core are cold-pressed bodies made of powder materials based on customized molds.

[0009] Furthermore, the U-shaped coil is a batch prefabricated part that is continuously bent and cut. The U-shaped coil is provided with a horizontal base that fits the bottom of the accommodating groove, vertical arm portions that are bent upward from both ends of the horizontal base, and pin portions that are bent outward from the top of the vertical arm portions. The pin portions are aligned and compatible with the positioning recess.

[0010] Furthermore, a spray paint layer is provided on the surface of the semi-finished product of the hot pressing package, and an electrode pad obtained by paint stripping and electroplating is provided at the end position corresponding to the U-shaped coil.

[0011] Furthermore, the long side walls and both ends of the U-shaped coil are formed into rounded corners on both sides of the formed electrode pad.

[0012] Compared with existing technologies, the advantages of this new uncoupled inductor are as follows: by disassembling the inductor structure and optimizing the shape of the prefabricated magnetic core and supporting coil, it helps reduce the space occupied by inductors in high-density PCBs. It also improves the performance of the inductor device, achieving a mutual coupling coefficient k less than 0.1. This further improves the circuit operating environment and promotes hardware performance development 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 This is a schematic diagram of the appearance evolution of the one-piece molded row-type uncoupled inductor of the utility model along the manufacturing process.

[0014] Figure 2 yes Figure 1 A close-up of the cup core structure in the inductor shown.

[0015] Figure 3 yes Figure 1 Schematic diagram of the forming structure of the U-shaped coil in the inductor shown.

[0016] Figure 4 yes Figure 1 Schematic diagram showing the data results of the Maxwell simulation test of the inductor shown. DETAILED DESCRIPTION

[0017] 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.

[0018] The utility model proposes an integrated molded row type uncoupled inductor. Figures 1 to 3 As shown, the basic structure of the inductor is formed by combining a pre-formed cup-shaped magnetic core 1, a magnetic core 3 and several U-shaped coils 2. From the perspective of the functional components of the preferred embodiment, the cup-shaped magnetic core 1 is a square block container with an open top surface. Four spaced-apart accommodating grooves 13a to 13d are provided in the cavity of the cup-shaped magnetic core, and all the accommodating grooves are parallel to the short side wall 11 of the cup-shaped magnetic core. The two ends of each accommodating groove are set as positioning notches 15 at the long side wall 12 of the cup-shaped magnetic core. The corresponding U-shaped coil 2 is formed by bending a copper strip, and its shape is suitable for falling into the accommodating groove and overlapping the two ends in the positioning notch. Finally, the magnetic core 3 is filled in the cavity of the cup-shaped magnetic core and the U-shaped coil is pressed into the accommodating groove, thereby eliminating the need to use additional components to fix the U-shaped coil, and at the same time realizing the basic structure of the inductor with the coil wrapped around the magnetic core. The two parts of the magnetic core are hot-pressed and packaged into one body, and the ends of the corresponding U-shaped coils are hot-pressed, painted, stripped, and then electroplated to form electrode pads 5.

[0019] On the basis of this prefabrication, the details of each functional component include: Figure 2 As shown, the cup-shaped magnetic core 1 is provided with an isolation boss 14 with increased wall thickness between two adjacent accommodating grooves. The inner wall spacing of the isolation boss 14 matches the spacing of one magnetic core 3 mounted therein. In other words, the isolation boss and the long side walls of the cup-shaped magnetic core form an accommodating groove, which stabilizes the U-shaped coils contained therein. Furthermore, slightly lowered positioning notches are provided on the top of the long side walls 12, adjacent to each isolation boss, to facilitate the overlapping and positioning of the two ends of the U-shaped coil and facilitate the production of electrode pads.

[0020] The U-shaped coil is a batch prefabricated part made by continuously bending and cutting copper strips. Figure 3 As shown, the U-shaped coil 2 is provided with a horizontal base 21 that fits the bottom of the receiving groove, vertical arm portions 22 that bend upward from both ends of the horizontal base, and pin portions 23 that bend outward from the top of the vertical arm portions. In this embodiment, the horizontal base 21 is set to be rounded and bent toward the vertical arm portion 22, and the corresponding positions of each receiving groove are also provided with matching arc surfaces. In addition, when the U-shaped coil is assembled into the receiving groove, the pin portion 23 can be aligned and compatible with the positioning recess of the cup-type magnetic core. On the one hand, when the I magnetic core is assembled, a semi-enclosed coil structure is formed. On the other hand, on the bottom surface of the two magnetic cores after hot pressing and packaging, the pin portion can occupy an appropriate area to facilitate the formation of the electrode pad.

[0021] As shown, the height of the single magnetic core 3, when installed within the cavity of the cup-shaped magnetic core 1, is sufficient to remain below the surface of the long side wall 12, forming a heat dissipation channel at the bottom of the inductor. The long side wall 12 and the ends of the U-shaped coil are rounded on either side of the formed electrode pad 5. This arrangement facilitates PCB assembly and reduces localized heat accumulation.

[0022] like Figure 1 As shown in the figure, further details of the features and complete manufacturing process are shown. After the cup core 1, U-shaped coil 2, and I-bar core 3 are assembled in sequence, a semi-finished assembly A is obtained. This assembly is then transferred into a packaging mold (not shown, but of matching dimensions) and encapsulated in a hot press environment at a temperature between 100-200°C and a pressure between 4-12 tons / cm². The molding time is typically between 30 and 180 seconds, but this time can be adjusted based on actual needs. After demolding, the product is then baked at 100-180°C for a period of time to fully cure and solidify, resulting in a semi-finished package B. This semi-finished package is then sprayed with insulating varnish 4 to coat its entire surface. Laser stripping is then performed on the corresponding locations of the semi-finished varnished body C. The exposed copper leads of the semi-finished body D are then electroplated to form clearly spaced electrode pads 5 on the bottom of the device. Of course, in addition to the above preferred embodiments, the number of pairs of the U-shaped coil and the accommodating slots in the cup-shaped magnetic core can be appropriately increased or decreased, so that 3 to 6 coil cores can be combined to form an integral inductor.

[0023] Both cores are assembled from powder materials and custom molds using a cold-pressing process. The powder materials used can be one or a mixture of iron powder, FeSi, FeSiCr, FeSiAl, FeNi, amorphous, or nanocrystalline. Resin is added, stirred, and then injected into a prefabricated mold designed to fit the device's shape. The molding pressure range is 6-10 tons / cm².

[0024] From the above detailed description of the preferred embodiment of the row-type uncoupled inductor of the utility model, it can be seen that compared with the existing technology, it has substantial characteristics and progress. Its technical effects are as follows: by disassembling the inductor structure and optimizing the shape of the prefabricated magnetic core and the supporting coil, it helps to reduce the space occupied by the inductor components in high-density PCBs, while improving the performance of the inductor device. Figure 4 Maxwell simulation tests of the inductor in this preferred embodiment show that the inductance values ​​of various components within the inductor device are nearly stable, and the mutual coupling coefficient k is less than 0.1. This can further improve the circuit operating environment and promote hardware performance development in application scenarios such as artificial intelligence (AI) servers, data centers, autonomous driving, and smart city transportation.

[0025] 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. One-piece molded row-type uncoupled inductor, characterized by: The inductor is formed by combining a preformed cup-shaped magnetic core, I magnetic core and several U-shaped coils, wherein the cup-shaped magnetic core is a rectangular container with an open top surface, and the cavity of the cup-shaped magnetic core is provided with more than three spaced-apart accommodating grooves, and all the accommodating grooves are parallel to the short side walls of the cup-shaped magnetic core, and the two ends of each accommodating groove are set as positioning notches on the long side walls of the cup-shaped magnetic core. The U-shaped coil is formed by bending a copper strip and the two ends are overlapped at the positioning notches, the I magnetic core is filled in the cavity of the cup-shaped magnetic core and the middle parts of all the U-shaped coils are pressed into the corresponding accommodating grooves, the two parts of the magnetic core are hot-pressed and packaged into one, and the ends of each U-shaped coil are set as electrode pads.

2. The one-piece molded row-type uncoupled inductor according to claim 1, characterized in that: The cup-shaped magnetic core is provided with an isolation boss with increased wall thickness between two adjacent accommodating grooves, and the inner wall spacing of the isolation boss matches that of one magnetic core to be installed therein.

3. The one-piece molded row-type uncoupled inductor according to claim 1, wherein: The height of the I magnetic core is such that the I magnetic core is lower than the surface of the long side wall when the core is loaded into the cup-shaped magnetic core cavity, thereby forming a heat dissipation channel at the bottom of the inductor.

4. The one-piece molded row-type uncoupled inductor according to claim 1, wherein: The cup core and the I-bar core are cold-pressed bodies made of powder material based on customized molds.

5. The one-piece molded row-type uncoupled inductor according to claim 1, characterized in that: The U-shaped coil is a batch prefabricated part that is continuously bent and cut. The U-shaped coil is provided with a horizontal base that fits the bottom of the accommodating groove, vertical arms bent upward from both ends of the horizontal base, and pins bent outward from the top of the vertical arms. The pins are aligned and compatible with the positioning recesses.

6. The one-piece molded row-type uncoupled inductor according to claim 1, characterized in that: The surface of the semi-finished product of the hot pressing package is provided with a spray paint layer, and an electrode pad obtained by paint stripping and electroplating is provided at the end position corresponding to the U-shaped coil.

7. The one-piece molded row-type uncoupled inductor according to claim 1, characterized in that: The long side walls and both ends of the U-shaped coil are formed into rounded corners on both sides of the formed electrode pad.

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