Coupling hot-pressing double inductor

Abstract

The utility model discloses a coupling hot-pressing double inductor which is composed of a T-shaped magnetic core, a cover type magnetic core and two coils which are preformed, the T-shaped magnetic core is provided with a bottom plate and a stand column body, the top face of the stand column body extends upwards in an integrated mode, and each coil is wound into a hollow spiral shape with more than three turns through a metal wire. The center axes of the spiral parts of the two coils coincide and are connected to the stand column body in a sleeved mode, the two ends of each coil extend in the same direction and are continuously bent to form a toggle clip, the toggle clips wrap the bottom plate and fix the coils to form an assembly, and the cover type magnetic core fully wraps the assembly in a hot-press forming mold and is packaged into a whole in a hot-press mode. And an electrode bonding pad communicated with the coil is arranged at the bottom of the position, corresponding to the toggle clip, of the double inductor. According to the utility model, the space occupied by the inductor in a high-density PCB (Printed Circuit Board) and the interference influence on the periphery can be reduced, and the performance of the inductor is improved, so that the mutual coupling coefficient k between the inductor is more than 0.98. And hardware performance development in various intelligent application scenes is facilitated.

Description

Technical Field

[0001] This utility model relates to an inductor device, and more particularly to a dual inductor device with low duty cycle and improved performance, belonging to the field of basic electronic components technology. Background Technology

[0002] Inductors are one of the most commonly used components in electronic devices, widely used in various circuits to perform functions such as filtering, energy storage, matching, and resonance. With the increasing miniaturization and portability of electronic products, and the high-density assembly of components, inductor components have developed rapidly. Furthermore, considering electromagnetic compatibility, the ability of electronic products to resist electromagnetic interference has become a basic design requirement, thus increasing the demand for and application of inductors.

[0003] Inductors are widely used in DC-DC converter buck circuits and play a crucial role in the circuit's conversion efficiency, thus constraining the development of big data processing hardware to some 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 desirable for each integrated inductor to operate independently to achieve the required function with minimal mutual interference. Furthermore, with the miniaturization demands of electronic products, inductors, as indispensable components in power supply systems, require not only high performance but also careful consideration of their shape and duty cycle. Inductor products need to achieve breakthroughs in all aspects, including stable performance parameters, durability, and installation compatibility. Summary of the Invention

[0004] The purpose of this invention is to propose a dual inductor suitable for high-density PCBs, aiming to improve the performance of inductor devices and their adaptability to various application scenarios.

[0005] The technical solution of this utility model to achieve the above-mentioned objective is: a coupled thermo-pressed dual inductor, characterized in that: the dual inductor is composed of a pre-formed T-shaped magnetic core, a cap-shaped magnetic core and two coils. The T-shaped magnetic core has a base plate and a column extending integrally with its top surface facing upward. The coils are made of metal wire wound into a hollow spiral shape with more than three turns, and the central axes of the spiral parts of the two coils coincide and are sleeved on the column. The two ends of each coil extend in the same direction and are continuously bent into a clip. The clip wraps around the base plate and fixes the coil to form an assembly. The cap-shaped magnetic core is fully wrapped in the assembly in a thermo-pressing mold and thermo-pressed into an integral unit. The bottom of the dual inductor at the position of the corresponding clip is provided with an electrode pad connected to the coil.

[0006] Furthermore, the height of the column is greater than the axial length of the coil, and the top of the column is joined to the inner wall of the cap-type magnetic core.

[0007] Furthermore, both the T-shaped magnetic core and the cap-shaped magnetic core are cold-pressed bodies made of powder material based on a customized mold.

[0008] Furthermore, the metal wire of the coil is a round copper wire with surface insulation treatment, and the two ends extending in the same direction are flattened and bent into a clip shape that is parallel to each other.

[0009] Furthermore, the metal wire of the coil is a flat copper wire with surface insulation treatment, and the two ends extending in the same direction are bent into a clip shape that is parallel to each other.

[0010] Furthermore, the inner bottom surface of the hot-press forming mold is provided with cross-shaped intersecting ribs, so that the areas where each clip is located are independently separated. The surface of the hot-press encapsulated dual inductor semi-finished product is provided with a paint layer, and the bottom is provided with electrode pads through paint peeling and electroplating.

[0011] Compared with existing technologies, the advantages of this dual inductor are as follows: by optimizing the shape of the prefabricated magnetic core, the assembly structure, and the shape of the matching coil, the product assembly stability and manufacturing consistency are guaranteed, which helps to reduce the space occupied by the inductor in high-density PCBs and the interference to the surrounding environment. At the same time, the two multi-turn coils are coaxially wound, which improves the performance of the inductor and makes the mutual coupling coefficient k inside the inductor greater than 0.98. This is conducive to further improving the circuit operating environment and promoting the development of hardware performance in application scenarios such as artificial intelligence servers / data centers / autonomous driving, smart city transportation, etc. Attached Figure Description

[0012] Figure 1 This is an exploded view of the structure of the coupled thermally pressed dual inductor of this utility model.

[0013] Figure 2 This is a schematic diagram illustrating the evolution of the external shape of the dual-inductor assembly and manufacturing process of this utility model. Detailed Implementation

[0014] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.

[0015] This invention proposes a coupled thermo-pressurized dual inductor. For example... Figure 1 and Figure 2As shown, the basic structure of this dual-inductor is formed by combining a pre-formed T-shaped magnetic core 1, a cap-type magnetic core 3, and two identical coils 2a and 2b. Looking at the unfolded functional components, the T-shaped magnetic core 1 has a base plate and a column 11 integrally formed with its top surface facing upwards; its shape can be cylindrical or square. Each coil is formed by winding metal wire into a hollow spiral shape with three or more turns. The spiral portions 21 of the two coils are stacked and interlocked to form a ring 2 with its central axis coinciding, and this ring is fitted onto the column 11. Due to the spiral winding, the coil has a free end on both the bottom and top sides, extending parallel to each other in the same direction. When it reaches a plane parallel to the central axis, it bends downwards for a distance. Obviously, the downward bend of the free end on the top side is longer, and the two free ends are then bent in the opposite direction to their previous extension at the same horizontal position, extending a distance to form a clip. This clip can wrap around the base plate and fix the coil to form component A. Finally, the cap-type magnetic core 3 is formed into a thin-walled cuboid container with a single-sided opening. After the above components are pre-loaded into the thermoforming mold (not shown), the cap-type magnetic core is also placed into the mold and inverted to fully enclose the components, and then thermo-pressed into a single unit. If necessary, as the basis for the inductor to connect to the PCB, it is also necessary to peel off the paint and electroplate the corresponding clip locations after thermo-pressing and painting to set the electrode pads connected to the coil.

[0016] Based on this overview of the technical solution, the detailed features of each functional component include: such as Figure 1 As shown, the base plate of the T-shaped magnetic core 1 is formed into a square shape. The two pairs of clips of the coil respectively clamp one pair of sides of the base plate. On the other hand, the height of the column 11 is preferably set to be slightly greater 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 cap-type magnetic core 3.

[0017] The metal wire of coil 2 is either surface-insulated round copper wire or flat copper wire; the preferred embodiment shown in the figure uses flat copper wire. Based on the winding and bending characteristics of the coil, the two coils used in this dual inductor are wound and bent in the same way. When they are assembled into a ring, the free end on the bottom side of one coil 2a is aligned with the free end on the top side of the other coil 2b on one side of the column, and the free end on the top side of one coil 2a is aligned with the free end on the bottom side of the other coil 2b on the other side of the column. Of course, if the metal wire of the coil is round copper wire, the ends extending in the same direction after winding can be flattened to facilitate subsequent bending and clamping.

[0018] Based on the aforementioned prefabrication and forming shape of the coil, it is important to understand that the coil forming is completed along with its assembly. That is, when it is fitted onto the column, the two free ends have not completed the full 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.

[0019] As a further optimization, the inner bottom surface of the hot-pressing mold is provided with cross-shaped intersecting ribs, so that the bottom of the hot-pressed inductor has a cross-shaped groove 4, which is independently separated from the area where each clip is located, providing convenience for subsequent paint peeling and electroplating, and also enabling the dual inductors to quickly release the heat generated during actual operation.

[0020] like Figure 2 As shown in the complete manufacturing process of this dual inductor, a T-shaped magnetic core, a cap-type magnetic core, and coils are prefabricated in the required proportions. Then, the two coils are overlapped and interlocked, and then fitted onto the pillar of the T-shaped magnetic core. All free ends are then bent close to the bottom surface of the base plate to achieve a clamping function and form component A. Next, the cap-type magnetic core is used to completely cover the assembly, which is then transferred to a thermoforming mold. The thermo-pressed semi-finished product B is obtained under a temperature of 100-200℃ and a pressure of 4-10 Tons / cm². The molding time is typically between 30 and 180 seconds, adjusted according to actual conditions. After demolding, the semi-finished product is baked at 100-180℃ for a period of time to completely solidify and set. Then, the surface of the inductor semi-finished product is sprayed with paint to obtain a fully covered insulating varnish 5, which is called the sprayed semi-finished product C. Next, laser stripping is performed on the location of the coil clip to obtain the exposed metal surfaces 22a, 22b, 23a, and 23b, which are the stripped semi-finished products D. Finally, these exposed copper surfaces are electroplated to generate clearly spaced electrode pads 6 at the bottom of the device, resulting in the dual inductor finished product E.

[0021] Both the aforementioned T-shaped and cap-type magnetic cores are prefabricated assemblies based on powder materials and custom molds, specifically using a cold-pressing process. The powder used for the magnetic core can be one or more mixtures of Fe-based / FeSi / FeSiCr / FeSiAl / FeNi / amorphous / nanocrystalline materials, with one of epoxy resin, silicone resin, or acrylic resin added and stirred evenly. It is then injected into a prefabricated mold conforming to the device's shape, with a selectable molding pressure range of 6-10 Tons / cm².

[0022] In summary, the preferred embodiment of this utility model for dual inductors in high-density PCBs demonstrates substantial features and advancements compared to existing technologies. Its technical effects include: optimizing the shape of the prefabricated magnetic core, the assembly structure, and the shape of the matching coils; ensuring product assembly stability and manufacturing consistency; reducing the space occupied by inductors in high-density PCBs and minimizing interference with surrounding components; and improving the performance of the inductor by having two multi-turn coils coaxially wound, resulting in an internal coupling coefficient k > 0.98. This is beneficial for further improving the circuit's operating environment and promoting hardware performance development in applications such as AI servers / data centers / autonomous driving, and smart city transportation.

[0023] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the principles of this application should be included within the protection scope of this application.

Claims

1. A coupled thermo-pressurized dual inductor, characterized in that: The dual inductor consists of a pre-formed T-shaped magnetic core, a cap-shaped magnetic core, and two coils. The T-shaped magnetic core has a base plate and a column extending integrally with its top surface facing upwards. The coils are made of metal wire wound into a spiral section with more than three turns and a central cavity. The spiral sections of the two coils are stacked and interlocked to form a ring with the central axis coinciding, and the ring is fitted onto the column. The two ends of each coil extend in the same direction and are continuously bent to form a clip. The clip wraps around the base plate and fixes the coil to form an assembly. The cap-shaped magnetic core is fully encapsulated in a hot-press molding mold and hot-pressed into an integral unit. The dual inductor has an electrode pad connected to the coil at the bottom of the corresponding clip position.

2. The coupled thermo-pressed dual inductor 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 joined to the inner wall of the cap-type magnetic core.

3. The coupled thermo-pressed dual inductor according to claim 1, characterized in that: Both the T-shaped magnetic core and the cap-shaped magnetic core are cold-pressed bodies made of powder material based on a customized mold.

4. The coupled thermo-pressed dual inductor according to claim 1, characterized in that: The coil's metal wire is a round copper wire with surface insulation treatment, and its two ends extending in the same direction are flattened and bent into a clip shape that is parallel to each other.

5. The coupled thermo-pressed dual inductor according to claim 1, characterized in that: The coil's metal wire is a flat copper wire with surface insulation treatment, and the two ends extending in the same direction are bent into a clip shape that is parallel to each other.

6. The coupled thermo-pressed dual inductor according to claim 1, characterized in that: The inner bottom surface of the hot-press forming mold is provided with cross-shaped protruding ribs, so that the areas where each clip is located are independently separated. The surface of the hot-press encapsulated dual inductor semi-finished product is provided with a paint layer, and the bottom is provided with electrode pads through paint peeling and electroplating.

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