Coupling-optimized inductor with two TLVRs integrated into one body

Abstract

The utility model discloses an inductor capable of optimizing coupling and integrating two groups of TLVRs. The inductor 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. Each primary coil is formed into a three-section body with the top and the bottom being bent in different directions, the surfaces of the three-section bodies are subjected to insulation treatment, and the two primary coils are embedded in the surface of one side and the bottom edge of the square primary magnetic core in parallel and at intervals. The secondary magnetic core is formed into a square body with the outer contour matched with that of the primary magnetic core, the two secondary coils wrap the secondary magnetic core in a non-closed-loop mode, the two magnetic cores are spliced in an edging mode and packaged into a whole in a hot pressing mode in the state that the two coils are attached back to back, and eight electrode bonding pads corresponding to all the coils are arranged on the two side faces of a packaging body. According to the inductor, the occupied space and the interference influence on the periphery can be reduced, meanwhile, the performance of an inductor device is improved, the coupling coefficient in the two coils in a single TLVR is larger than 0.94, the coupling coefficient between the two TLVRs is smaller than 0.1, and the operation environment of a circuit is further improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to an inductor, especially to a multi-integrated inductor with improved coupling performance between two-stage coils, and belongs to the technical field of basic electronic components. BACKGROUND

[0002] Inductors are the most commonly used components in electronic devices, and are widely used in various circuits to achieve the functions of filtering, energy storage, matching and resonance. With the miniaturization and high-density assembly of electronic products, inductors have developed rapidly. In addition, considering electromagnetic compatibility, the anti-electromagnetic interference capability of electronic products has become a basic design requirement, which has increased the demand and application of inductors.

[0003] TLVR (Trans-Inductor Voltage Regulator) architecture is a rising VR (Voltage Regulator) power supply architecture. The biggest difference between it and traditional DC to DC Buck and DC architectures is that the traditional single-winding ordinary inductor is improved to a TLVR inductor with double-winding similar to a transformer. The ordinary inductor has only one set of winding matched with two pins, while the TLVR inductor has two sets of mutually coupled windings matched with four pins. There is a great difference in structure between the two.

[0004] Currently, in the industry, when designing the structure of TLVR inductors, in addition to the main goal of improving the coupling efficiency between two-stage coils, the number and space occupied by components in high-density PCBs are also the focus of attention. Therefore, the multi-integration and coupling coefficient optimization of TLVR inductors in limited space have become a technical gap that needs to be filled in the industry. SUMMARY

[0005] The utility model aims to provide an inductor with optimized coupling and two sets of TLVR integrated into one, which is committed to improving the performance of inductors and optimizing the space occupied by components in high-density PCBs.

[0006] The utility model discloses a technical solution for realizing the above-mentioned purpose is: a kind of inductor of optimization coupling and two groups TLVR integrated one, by preformed primary magnetic core, secondary magnetic core, primary coil and secondary coil combination forming, the primary coil is formed as the three-segment body of the top and bottom bending direction difference and surface insulation treatment, two primary coils are inlaid in the side surface and bottom edge of square primary magnetic core in parallel and interval, the secondary magnetic core is formed as the square body of the outer contour matching primary magnetic core and two secondary coils are non-closed loop type around secondary magnetic core, in the state that two primary coils are back-to-back adhered, two magnetic cores are edge-to-edge spliced and hot-press encapsulation into an organic whole, four electrode pads of secondary coil and each one electrode pad of two primary coils are arranged on the side surface of encapsulation body, and the other one electrode pad of two primary coils is arranged on the other side surface of encapsulation body.

[0007] Further, one side surface of the primary magnetic core is provided with two first accommodating grooves, the depth and width of each first accommodating groove are adapted to accommodate the primary coil therein, and the upper end of each first accommodating groove is flush with the top edge of the primary magnetic core, and the lower end of each first accommodating groove is bent and extended to the other side surface of the primary magnetic core.

[0008] Further, one side surface of the secondary magnetic core is provided with two second accommodating grooves which are bent and extended to the other side surface and integrally present an open ring shape, the depth and width of each second accommodating groove are adapted to accommodate the secondary coil therein, and the depth of the notch groove formed at the upper end of each second accommodating groove is greater than the sum of the thicknesses of the two primary coils, and the depth of the notch groove formed at the lower end of each second accommodating groove is adapted to accommodate the bent and wrapped secondary coil.

[0009] Still further, the two side edges of the primary magnetic core and the secondary magnetic core are provided with step grooves for alignment and splicing, and a C-shaped clamping buckle is sleeved in each step groove in the edge-to-edge splicing state of the two magnetic cores.

[0010] Still further, the primary magnetic core and the secondary magnetic core are both hot-press forming bodies based on a customized mold from a powder material.

[0011] Further, the primary coil is a kind of multipurpose accessory cut from a flat copper strip and continuously bent and formed, and the surface of the primary coil is sprayed with an epoxy resin insulation layer with a thickness of 0.02-0.08 mm.

[0012] Further, the secondary coil is another kind of multipurpose accessory cut from a flat enameled wire and bent and formed, and the enameled film thickness of the secondary coil is 0.025-0.055 mm.

[0013] Further, the two primary coils are partially stripped of paint and electroplated to form electrode pads on the two side surfaces of the encapsulation body, and the two primary coils are subjected to stripping treatment to increase the insulation distance near the two primary coils.

[0014] Compared with the prior art, the inductor has the advantages that: by optimizing the prefabricated shape and assembly structure of the two-stage magnetic core and the coil, on the one hand, the product assembly stability and manufacturing consistency are guaranteed, which helps to reduce the space occupied by the inductor in the high-density PCB and the interference influence on the periphery, on the other hand, the coils and the two-stage coils are reliably isolated, the coupling coefficient of the single TLVR is greater than 0.94, and the mutual coupling coefficient between the two TLVRs is less than 0.1, further improving the running environment of the circuit and promoting the development of hardware performance in the application scenarios of artificial intelligence AI server / data center / automatic driving, smart city traffic and the like. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a close-up structure schematic view of the primary magnetic core in the preferred embodiment of the inductor of the utility model.

[0016] Figure 2 is a close-up structure schematic view of the secondary magnetic core in the preferred embodiment of the inductor of the utility model.

[0017] Figure 3 is a close-up structure schematic view of the primary coil in the preferred embodiment of the inductor of the utility model.

[0018] Figure 4 is a close-up structure schematic view of the secondary coil in the preferred embodiment of the inductor of the utility model.

[0019] Figure 5 is an appearance evolution schematic view of the assembly and manufacturing of the preferred embodiment of the inductor of the utility model.

[0020] Figure 6 is a positioning and electrode pad forming structure schematic view between the two-stage coils in the finished product of the inductor of the utility model. DETAILED DESCRIPTION

[0021] In order to enable personnel in the art to better understand the present application scheme, the technical solutions in the present application embodiment will be clearly and completely described below in conjunction with the drawings in the present application embodiment.

[0022] The utility model proposes an inductor which is optimized in coupling and integrates two groups of TLVRs, and is dedicated to improving the inductor performance and optimizing the space occupied by the components in the high-density PCB. Figures 1 to 5As shown, the basic structure of the inductor is assembled by pre-formed primary core 1, secondary core 2, primary coil 3 and secondary coil 4, and obtained by a series of process technologies such as hot pressing assembly, paint spraying, partial paint stripping, electroplating, etc. In summary, the primary core 1 has a square body shape, one side surface is flat, and the other side surface is provided with two parallel and spaced first containers. The first container is integrally extended by the vertical part 11 and the horizontal bending part 12 near the bottom edge of the primary core. Correspondingly, the primary core 3 is formed as a three-segment body with different bending directions at the top and bottom and surface insulation treatment. Specifically as Figure 3 As shown, the primary core 3 includes a middle vertical segment 31, a top front folding segment 32 and a bottom rear folding segment 33. From the assembly point of view, two primary coils 3 are parallel and spaced and embedded in the primary core one side surface and the bottom edge. The middle vertical segment is compatible with the vertical part of the first container, the bottom rear folding segment is compatible with the horizontal bending part of the first container, and the top front folding segment is suspended and exposed. On the other hand, the secondary core 2 is formed as a square body with an outer contour matching the primary core, and one side surface is provided with two parallel and spaced second containers 21, and the two ends of any one second container are bent and extended to the other side surface to become a pair of concave tables 22. Correspondingly, two secondary coils 4 are non-closed loop bending wrapped around the secondary core corresponding to the shape of the second container; specifically as Figure 4 As shown, the secondary core 4 includes a main body segment 41 falling into the second container, and a top folding segment 42 and a bottom folding segment 43 wrapped in the recess. On the basis of pre-assembly of two-stage core and coil, two cores are edge-to-edge spliced in the state of two-stage coil back-to-back contact. At this time, the top front folding segment of the primary coil is located in the top side space of the secondary core second container. Finally, hot-press packaging into one body. As the basis of the inductor into the PCB, four electrode pads B corresponding to the secondary coil and one electrode pad A1 of each of the two primary coils are provided on one side of the packaging body, and the other electrode pad A2 of each of the two primary coils is provided on the other side of the packaging body. Here, the four electrode pads of the primary coil can also be uniformly marked as A.

[0023] Considering the design of two groups of integrated and batch production, the above two-stage core and two-stage coil can be batch pre-fabricated and reused. Based on the summary of the technical scheme and the preferred embodiment diagram, the details of the features of each functional component of the inductor also include: Figure 3 As shown, the primary coil is a reusable accessory cut from a flat copper strip and continuously bent into shape, and the primary coil surface is sprayed with an epoxy resin insulation layer with a thickness of 0.02-0.08mm, aiming to strengthen the insulation between the primary and secondary coils. On the other hand, Figure 4The secondary coil is another complex accessory cut from flat enameled wire and bent into shape, and the thickness of the enamel film of the secondary coil is between 0.025-0.055mm. As can be seen from the comparison, the thickness of the primary coil is greater than that of the secondary coil.

[0024] The two first accommodating grooves arranged on the primary magnetic core are adapted to accommodate the primary coil therein, and the depth and width of each first accommodating groove are adapted to the primary coil. The upper end of each first accommodating groove is flush with the top edge of the primary magnetic core, and the lower end of each first accommodating groove is bent to extend to the other side surface of the primary magnetic core, i.e. the above-mentioned transversely bent portion opening downward, for positioning the bottom rear bent segment of the primary coil therein. Similarly, the side surface of the secondary magnetic core is provided with two second accommodating grooves bent to extend to the other side surface and integrally forming an open ring, and the depth and width of each second accommodating groove are adapted to accommodate the secondary coil therein. The depth of the notch formed at the upper end of each second accommodating groove is greater than the sum of the thicknesses of the two coils, i.e. adapted to accommodate the secondary coil bent around and the top front bent segment of the primary coil therein, and the depth of the notch formed at the lower end of each second accommodating groove is adapted to accommodate the secondary coil bent around and flush with the bottom edge of the secondary magnetic core.

[0025] As can be seen from the preferred embodiment shown by Figure 1 and Figure 2 , the two side edges of the primary magnetic core 1 are further provided with a part of stepped grooves 13, and the two side edges of the secondary magnetic core 2 are further provided with another part of stepped grooves 23. The two parts of stepped grooves can be aligned and combined in the combined state of the two magnetic cores, and a C-shaped clamping buckle 5 is sleeved on each side stepped groove, so that the two magnetic cores are clamped and fastened. The two-stage magnetic cores of the above-mentioned preferred embodiment are assembly parts based on powder material and customized mold, and the cold pressing forming process is used. The powder material used for the magnetic core can be one or more than two kinds of mixture of Fe-based / FeSiCr / FeSiAl / FeSi / amorphous / nanocrystalline, and one of epoxy resin, silicone resin or acrylic resin is added and stirred uniformly and then injected into the customized mold arranged according to the shape of the device, and the forming pressure range is 6-10Tons / cm².

[0026] The utility model is dedicated to optimizing the coupling performance of multiple integrated TLVR inductors, and on the basis of the surface film plating of the primary coil, as shown in Figure 6 , on the basis of the combined and hot-pressed packaging of the two-stage magnetic cores, the gap Q between the two-stage magnetic cores is close to zero, which is beneficial to improve the coupling coefficient of a single TLVR. On the other hand, the two-stage coils are partially stripped of paint on the two side surfaces of the packaging body and are plated into electrode pads, and the stripping treatment is performed to increase the insulation distance near the two-stage coils. Figure 6As shown in the upper left corner, the primary coil is stripped on the entire surface of the top front folded section, while the secondary coil is stripped only on the part of the outer surface of the top folded section away from the primary coil, and the two stripped parts are isolated by a certain distance.

[0027] As shown in the upper left corner, the primary coil is stripped on the entire surface of the top front folded section, while the secondary coil is stripped only on the part of the outer surface of the top folded section away from the primary coil, and the two stripped parts are isolated by a certain distance. Figure 5 As shown in the upper left corner, the primary coil is stripped on the entire surface of the top front folded section, while the secondary coil is stripped only on the part of the outer surface of the top folded section away from the primary coil, and the two stripped parts are isolated by a certain distance.

[0028] As shown in the upper left corner, the primary coil is stripped on the entire surface of the top front folded section, while the secondary coil is stripped only on the part of the outer surface of the top folded section away from the primary coil, and the two stripped parts are isolated by a certain distance.

[0029] 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. An optimized coupled and two sets of TLVR integrated in one inductor, characterized by: The inductor is formed by combining a preformed primary magnetic core, a secondary magnetic core, a primary coil and a secondary coil, the primary coil is formed into three segments with the top and bottom bending directions being different and the surface being insulated, two primary coils are embedded in parallel and at intervals on one side surface and the bottom edge of the square primary magnetic core, the secondary magnetic core is formed into a square body with the outer contour matching the primary magnetic core and two secondary coils are non-closed loop wrapped around the secondary magnetic core, the two magnetic cores are combined edge-to-edge in the state of two-stage coil back-to-back adhesion and are hot-pressed and packaged into an integrated body, four electrode pads of the secondary coil and one electrode pad of each of the two primary coils are arranged on one side surface of the packaging body, and the other electrode pad of each of the two primary coils is arranged on the other side surface of the packaging body.

2. The integrated inductor with optimized coupling and two sets of TLVRs according to claim 1, characterized in that: One side surface of the primary magnetic core is provided with two first accommodating grooves, the depth and width of each first accommodating groove are adapted to accommodate the primary coil therein, and the upper end of each first accommodating groove is flush with the top edge of the primary magnetic core, and the lower end of each first accommodating groove is bent and extended to the other side surface of the primary magnetic core.

3. The integrated inductor with optimized coupling and two sets of TLVRs according to claim 1, wherein: One side surface of the secondary magnetic core is provided with two second accommodating grooves which are bent and extended to the other side surface and are in the form of an open ring as a whole, the depth and width of each second accommodating groove are adapted to accommodate the secondary coil therein, and the depth of the notch groove formed at the upper end of each second accommodating groove is greater than the sum of the thicknesses of the two-stage coil, and the depth of the notch groove formed at the lower end of each second accommodating groove is adapted to the bent wrapping of the secondary coil.

4. The integrated inductor of claim 1, 2 or 3, wherein: The two side edges of the primary magnetic core and the secondary magnetic core are provided with step grooves for alignment and splicing, and a C-shaped clasp is sleeved in each step groove in the edge-to-edge splicing state of the two magnetic cores.

5. The integrated inductor of claim 1, 2 or 3, wherein: the first and second sets of TLVRs are coupled in series. The primary magnetic core and the secondary magnetic core are both hot-pressed bodies formed based on a customized mold from a powder material.

6. The integrated inductor with optimized coupling and two sets of TLVRs according to claim 1, characterized in that: The primary coil is a kind of complex accessory cut from a flat copper strip and continuously bent into shape, and the primary coil surface is sprayed with an epoxy resin insulation layer with a thickness of 0.02-0.08mm.

7. The integrated inductor with optimized coupling and two sets of TLVRs according to claim 1, characterized in that: The secondary coil is another kind of complex accessory cut from a flat enameled wire and bent into shape, and the enameled wire thickness of the secondary coil is 0.025-0.055mm.

8. The integrated inductor with optimized coupling and two sets of TLVRs according to claim 1, wherein: The two-stage coil is partially stripped of paint and electroplated into an electrode pad on the two side surfaces of the packaging body, and the paint stripping treatment is performed near the two-stage coil to increase the insulation distance.

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