Inductance device integrally formed by hot pressing
By using a thermo-pressed integrated inductor, the assembly structure of the magnetic core and metal coil is optimized, solving the problems of size and current specifications of inductors in miniaturized and high-performance circuits, and realizing high density and high performance of inductor devices.
Patent Information
- Application Number
- CN202423020814.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-09
- Publication Date
- 2026-01-02
- Estimated Expiration
- 2034-12-09
AI Technical Summary
In the process of miniaturization and high-performance development of electronic products, existing inductor devices are unable to meet the requirements of reducing size and increasing current specifications, especially in the multi-phase conversion circuits of CPU and GPU core power supplies, where existing technologies cannot effectively solve the problem.
The inductor, which is integrally formed by thermoforming, consists of several pre-formed magnetic cores and metal coils. By optimizing the shape and assembly structure of the magnetic cores and combining them with the shape of the metal coils, they are thermo-pressed together to form a tightly integrated inductor.
It improves the magnetic powder density and performance of inductors, optimizes the circuit operating environment, and promotes the development of hardware performance.
Smart Images
Figure CN223757362U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to a kind of power magnetic components, especially a kind of power inductive device of hot-pressing integrated molding, belong to basic electronic components technical field. BACKGROUND
[0002] In recent years, electronic industry and its products develop rapidly. Such as four service server application, AI artificial intelligence related equipment, cloud server, internet gateway and terminal machine etc. product, under the premise of product volume reduction, parameter performance requirement and precision improvement, how to improve product power density becomes one of main technical research directions.
[0003] Under such development environment premise, passive components such as magnetic components in power supply circuit also develop towards miniaturization, high efficiency, low power consumption. In the mainboard of computer, AIPC, server, AI equipment mainboard and APU power supply scheme is highly integrated, its periphery inductance develops from original assembly inductor to molding inductor in recent years, and to mini-molding inductor in the future. This is towards the direction of improving product power density, reducing product volume, which is beneficial to reduce circuit space occupation. Especially limited by the appearance size of terminal equipment and the complexity of internal mechanism design, the multi-phase conversion circuit applied to CPU and GPU core power supply increases with the increase of power consumption. The size and current specification requirements of inductive device are also increased. SUMMARY
[0004] The utility model aims at providing a kind of inductive device of hot-pressing integrated molding, dedicated to improving inductor performance and each application scene adaptation ability.
[0005] The technical solution for achieving the above-mentioned purpose of the utility model is: the inductive device of hot-pressing integrated molding is composed of a plurality of magnetic core bodies and metal coils that are pre-formed in a split manner. It includes a first magnetic core body with a groove, a second magnetic core body with a main body in the shape of a cylindrical body, and a third magnetic core body in the shape of a sheet. The metal coil has a hollow spiral winding segment, and the winding segment is compatible with the groove of the first magnetic core body. The two ends of the winding segment are shaped as continuous bending segments, and the end portions of the continuous bending segments serve as electrodes of the inductive device, exposed on the outside of the first magnetic core body. The main body of the second magnetic core body penetrates the cavity of the winding segment. The third magnetic core body covers the open end of the groove of the first magnetic core body and covers the second magnetic core body and the metal coil except for the end portion. The assembled body is hot-pressed and packaged into an integrated body in a molding mold.
[0006] Further, the groove of the first magnetic core body is provided through the bottom, the second magnetic core body is formed with a matching groove inner profile bottom disc at one end of the columnar body, the first magnetic core body is sleeved on the second magnetic core body and the groove wraps the bottom disc, the winding segment of the metal coil is arranged in the gap between the groove and the columnar body, and the end of the continuous bending segment is exposed to the outside of the first magnetic core body, and the third magnetic core body is covered on the groove opening of the combination of the first magnetic core body, the second magnetic core body and the metal coil.
[0007] Further, the groove of the first magnetic core body is provided through the bottom, the second magnetic core body is formed with a matching groove inner profile bottom disc at one end of the columnar body, the first magnetic core body is sleeved on the second magnetic core body and the groove wraps the bottom disc, the winding segment of the metal coil is arranged in the gap between the groove and the columnar body, and the end of the continuous bending segment is exposed to the outside of the first magnetic core body, and the third magnetic core body is covered on the groove opening of the combination of the first magnetic core body, the second magnetic core body and the metal coil.
[0008] Further, the groove of the first magnetic core body is provided through the bottom, the second magnetic core body is formed with a matching groove inner profile bottom disc at one end of the columnar body, the first magnetic core body is sleeved on the second magnetic core body and the groove wraps the bottom disc, the winding segment of the metal coil is arranged in the gap between the groove and the columnar body, and the end of the continuous bending segment is exposed to the outside of the first magnetic core body, and the third magnetic core body is covered on the groove opening of the combination of the first magnetic core body, the second magnetic core body and the metal coil.
[0009] Further, the first magnetic core body, the second magnetic core body and the third magnetic core body are all cold-pressed forming bodies based on the shape of the iron-based soft magnetic powder material.
[0010] Further, the metal coil is formed by winding and bending a metal wire covered with an insulation layer, and the shape of the metal coil includes a laminated winding type based on a flat wire-shaped metal wire, a double-layer laminated winding type, an inner-outer double-layer laminated winding type and a single-layer laminated winding type based on a round wire-shaped metal wire.
[0011] Further, the end of the metal coil is led out from the same height position above the winding segment.
[0012] Further, the surface of the hot-pressing packaged integrated semi-finished product is coated with an insulating paint, and the electrode is exposed by stripping the paint at the position of the end of the metal coil.
[0013] Compared with the prior art, the advantages of the hot-pressing integrated inductor device of the utility model are that by optimizing the shape and assembly structure of the prefabricated magnetic core body and the shape of the matched metal coil, the position of the metal coil can be effectively controlled, the density of the magnetic powder in the product and the performance of the inductor device are improved, the operation environment of the circuit is improved, and the development of the hardware performance in the current multiple application scenarios is promoted. BRIEF DESCRIPTION OF DRAWINGS
[0014] Figure 1 is a perspective structural schematic view of the inductor device finished product of the utility model.
[0015] Figure 2 is Figure 1 is a top view structural schematic view of the inductor device finished product.
[0016] Figure 3 is Figure 2 is a structural sectional view along A-A line of the inductance device finished product shown in
[0017] Figure 4 is a schematic diagram of the explosion structure of a preferred embodiment of the present application.
[0018] Figure 5 is Figure 4 is a structural schematic diagram of the first magnetic core body, the second magnetic core body and the metal coil assembly semi-finished product in the preferred embodiment shown.
[0019] Figure 6 is a schematic diagram of the explosion structure of a preferred embodiment of the present application.
[0020] Figure 7 is a schematic diagram of the explosion structure of another preferred embodiment of the present application.
[0021] Figure 8 is a schematic diagram of the explosion structure of another preferred embodiment of the present application.
[0022] Figure 9 is a winding structure schematic diagram of the metal coil in the inductance device of the present application. DETAILED DESCRIPTION
[0023] In order to enable the persons skilled in the art to better understand the present application scheme, the technical solutions in the present application embodiments will be clearly and completely described below in conjunction with the drawings in the present application embodiments.
[0024] The present application designs and proposes an inductance device integrally formed by hot pressing, which is composed of a plurality of magnetic core bodies and metal coils assembled by pre-pressing forming, and the design shape of each magnetic core body and the shape and size of the metal coil are mutually matched, and the assembly semi-finished product is tightly combined into an integrated body after being formed by heating and pressing. The perspective, top view and surface structure of the inductance device are shown in Figures 1 to 3 .
[0025] As shown in Figure 4The preferred embodiment of the hot-pressing integrated inductor device is shown in the explosion structure schematic diagram and the partially assembled semi-finished product structure schematic diagram. It comprises a first magnetic core body 31 with a groove, a second magnetic core body 32 in the shape of a columnar body and a third magnetic core body 33 in the shape of a sheet. The metal coil 34 is provided with a hollow spiral winding section and two continuous bending sections at the ends. The outer diameter of the winding section matches the inner diameter of the groove of the first magnetic core body (the actual size is the span between the inner walls), so that the winding section is adapted to be compatible with the groove. The inner diameter of the winding section matches the outer diameter and shape of the columnar body of the second magnetic core body, so that the columnar body is adapted to be inserted into the cavity of the winding section. At the same time, the third magnetic core body 33 covers the groove opening of the first magnetic core body 31 and covers the second magnetic core body 32 and the metal coil 34 except the end part.
[0026] In actual assembly, the metal coil obtained by winding is assembled and combined with the second magnetic core body, and then is placed in the groove of the first magnetic core body, to obtain an assembled semi-finished product 311 as shown in Figure 5 . Then the third magnetic core body 33 with the same size as the groove opening and in the shape of a round sheet is covered on it, and as shown in the figure, the two continuous bending sections of the metal coil are exposed on the outside from the junction of the first magnetic core body and the third magnetic core body. Finally, the four-part complete assembly is transferred into a hot-pressing forming mold. The integrated encapsulation is performed in a temperature and pressure environment with a temperature of 150-200 DEG C and a pressure of 5-15 tons / cm². The molding time is usually 60-120 seconds, which can be adjusted according to the actual situation. After the product is demolded, it is baked at a temperature of 100-180 DEG C for a period of time to completely cure and set. Then the surface of the inductor device semi-finished product is subjected to full-coverage paint spraying to form an insulating paint. After the insulating paint is completely cured, the first end part 341 and the second end part 342 of the continuous bending section are subjected to laser paint stripping to expose the metal surface, and then are subjected to electroplating treatment to form electrodes for welding.
[0027] As shown in Figure 6 , a preferred embodiment is also assembled and hot-pressing integrated by four pre-formed components. Specifically, the groove of the first magnetic core body is provided with a bottom, that is, a sleeve type magnetic core body 41, and the second magnetic core body is provided with a matching groove inner profile disc at one end of the columnar body, that is, a T-shaped magnetic core body 42. The overall shape of the metal coil 34 and the third magnetic core body 33 in this embodiment is the same as that of the preferred embodiment. In actual assembly, the first magnetic core body is sleeved on the second magnetic core body and the groove wraps the disc, the winding section of the metal coil is assembled into the gap between the groove and the columnar body, and the end parts of the two continuous bending sections are exposed on the outside of the first magnetic core body. The third magnetic core body covers the groove opening of the combination of the first magnetic core body, the second magnetic core body and the metal coil. The subsequent process is the same as that of the preferred embodiment, and the detailed description is omitted.
[0028] As Figure 7 shown in another preferred embodiment, the difference between it and the embodiment shown in Figure 6 is that its T-shaped magnetic core body is divided into two parts, making an independent magnetic core body part with a single column 52 and a sheet 53. Among them, the first magnetic core body shape is referred to the embodiment shown in Figure 6 is set as a hollow block type magnetic core body 51, and the overall shape of the metal coil 34 and the third magnetic core body 33 is set as the preferred embodiment. Obviously, the shape and size of the third magnetic core body 33 is different from that of the sheet 53, the former corresponds to the hollow shape of the first magnetic core body, and the latter corresponds to the overall shape of the first magnetic core body. In actual assembly, the metal coil is first assembled and combined with the single column 52, and then the two combined parts are assembled and combined with the hollow block type magnetic core body; then the sheet is clamped on the bottom and the third magnetic core body is clamped on the top, and the three combined parts are transferred into the hot-press packaging process.
[0029] As Figure 8 shown in another preferred embodiment, the difference between it and the preferred embodiment is that the first magnetic core body with a groove is provided with two first and second notches 611 and 612 on the side of the groove opening, that is, the depth of the sleeve shell type magnetic core body 61 is customized. The second magnetic core body and the third magnetic core body are combined into one, forming a cover type magnetic core body 62 with a middle column. On the basis of no significant change in the overall shape of the metal coil, in actual assembly, the cover type magnetic core body is first inserted into the winding section from top to bottom, and then the combined body is inserted into the groove of the sleeve shell type magnetic core body, and the first end 341 is aligned and compatible with the first notch 611, and the second end 342 is aligned and compatible with the second notch 612, to complete the assembly and then transfer into the hot-press packaging process.
[0030] The above multiple embodiments are for ease of illustration, wherein the grooves of each magnetic core body and the cross section of the columnar body are circular, but the internal structure design of the inductor device is not limited to this, that is, the top view shape of the groove in the first magnetic core body can also be square, oval or triangular, and the shape of the columnar body in the second magnetic core body can also be selected as a square column, an oval column, a cross-shaped column or a rounded square column, and the profile size of the columnar body is matched and compatible with the axial cavity of the winding section. The magnetic core bodies are all assembled parts obtained by Fe-based soft magnetic powder material and customized mold, and the powder material used can be one or more than two kinds of mixture of Fe-based / FeSi / FeSiCr / FeSiAl / FeNi / amorphous / nanocrystalline, and 1.5%-4.5% of one of epoxy resin, silicone resin or acrylic resin per unit weight is added and stirred uniformly and then injected into the preformed mold set according to the shape of the device. The cold pressing process is used, and the optional forming pressure range is 6-10Tons / cm².
[0031] The metal coil in the inductance device is made based on multiple materials and winding modes. Figure 9 The forming shape of the metal coil based on the self ductility includes a laminated winding type 71 based on a flat wire metal conductor, a double-layer laminated winding type 72, an inner and outer double-layer winding type 74 and a single-layer winding type 73 based on a round wire metal conductor.
[0032] From the consistent aspect, the two ends of the metal coil are led out from the same height position above the winding section.
[0033] The inductance device of the utility model is integrated by hot pressing, and the advantages are embodied in the following aspects: by optimizing the shape and assembly structure of the prefabricated magnetic core body and the shape of the matched metal coil, the position of the metal coil can be effectively controlled, the density of the magnetic powder in the product and the performance of the inductor are improved.
[0034] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Those skilled in the art can make various changes and modifications to the present application. Any modification, equivalent replacement, improvement, etc. within the principles of the present application shall be included in the protection scope of the present application.
Claims
1. A hot-press integrated inductor device, which is composed of several magnetic core bodies and metal coils which are pre-formed separately, characterized in that: The metal coil is wound and bent by a metal wire with an insulating layer, and the shape of the metal coil includes a laminated winding type based on a flat wire metal wire, a double-layer laminated wrapping winding type, an inner and outer double-layer wrapping winding type, and a single-layer wrapping winding type based on a round wire metal wire.
2. The integrally thermoformed inductor device of claim 1, wherein: The recess of the first magnetic core body is provided through the bottom, the second magnetic core body is formed with a chassis matching the inner profile of the recess at one end of the columnar body, the first magnetic core body is sleeved on the second magnetic core body and the recess wraps the chassis, the winding segment of the metal coil is installed in the gap between the recess and the columnar body, and the end of the continuous bending segment is exposed outside the first magnetic core body, and the third magnetic core body covers the recess opening of the first magnetic core body after being combined with the second magnetic core body and the metal coil.
3. The integrally thermoformed inductor device of claim 1, wherein: The top view shape of the recess in the first magnetic core body is square, circular, oval or triangular, and a slot compatible with the corresponding end is provided on the side of the recess opening.
4. The integrally thermoformed inductor device of claim 1, wherein: The outer shape of the columnar body in the second magnetic core body is a square column, a circular column, an elliptical column, a cross-shaped column or a round square column, and the profile size of the columnar body matches the axial cavity of the winding segment.
5. The integrally thermoformed inductor device of claim 1, wherein: The first magnetic core body, the second magnetic core body and the third magnetic core body are all cold-pressed bodies based on the shape of the iron-based soft magnetic powder material.
6. The integrally thermoformed inductor device of claim 1, wherein: The metal coil is wound and bent by a metal wire with an insulating layer, and the shape of the metal coil includes a laminated winding type based on a flat wire metal wire, a double-layer laminated wrapping winding type, an inner and outer double-layer wrapping winding type, and a single-layer wrapping winding type based on a round wire metal wire.
7. The integrally thermoformed inductor device of claim 6, wherein: The end of the metal coil is led out from the same height position above the winding segment.
8. The integrally thermoformed inductor device of claim 1, wherein: The surface of the semi-finished product packaged by hot pressing is coated with an insulating paint, and the electrode is exposed by stripping the paint at the position of the end of the metal coil.