Large-current coupling inductor

Abstract

The utility model discloses a large-current coupling inductor which comprises a first alloy magnetic core, a second alloy magnetic core and copper sheet windings, wherein the first alloy magnetic core and the second alloy magnetic core are arranged in a stacked mode, and the copper sheet windings are installed in the first alloy magnetic core and the second alloy magnetic core. Glass beads which are uniformly distributed are filled between two opposite surfaces of the first alloy magnetic core and the second alloy magnetic core; the first alloy magnetic core is provided with a first mounting hole for mounting the copper sheet winding, and the second alloy magnetic core is provided with a second mounting hole for mounting the copper sheet winding; the copper sheet winding comprises a primary winding composed of two first copper sheets and a secondary winding composed of two second copper sheets, the first copper sheets and the second copper sheets are arranged in parallel, and the two first copper sheets are located between the two second copper sheets; all the components are assembled and bonded into a whole through epoxy resin. The inductor provided by the utility model can realize rapid load transient response under the condition of reducing output capacitance as much as possible.

Description

Technical Field

[0001] This utility model relates to the field of electronic components technology, specifically to a high-current coupled inductor. Background Technology

[0002] Voltage regulators and power management units play a crucial role in modern electronic devices and power systems, especially in high-performance computing, communications, and consumer electronics. As electronic devices increasingly demand fast response and high efficiency, traditional circuit design faces numerous challenges.

[0003] The transient response of traditional circuits largely relies on capacitor banks at the circuit output. These capacitors are typically made of polymer materials to provide the necessary filtering and energy storage functions. However, polymer capacitors are subject to degradation over time; their capacitance and performance may decrease significantly over time, affecting the stability and reliability of the circuit. Furthermore, the presence of the output filter inductance hinders the rapid current rise from the regulator. When the load changes rapidly, the regulator may struggle to provide the required current in time, causing instantaneous fluctuations in the output voltage, which is unacceptable for high-performance systems.

[0004] To improve the transient response of a system, traditional designs typically increase the output capacitor's capacitance. However, this approach not only increases the system's physical size and cost but may also reduce the power density of the power supply. Larger capacitors also introduce additional power consumption during charging and discharging, thus reducing the overall system efficiency. Therefore, achieving fast load transient response while minimizing the output capacitor has become a pressing problem to be solved.

[0005] Therefore, this invention proposes a high-current coupled inductor that, through an innovative inductor topology design, can be used in conjunction with a multiphase buck converter to minimize output capacitance requirements while providing a very fast load transient response. Utility Model Content

[0006] The purpose of this invention is to provide a high-current coupled inductor that can achieve a fast load transient response while minimizing output capacitance.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A large-current coupling inductor includes a first alloy magnetic core and a second alloy magnetic core arranged in a stacked manner, and a copper sheet winding installed in the first alloy magnetic core and the second alloy magnetic core; glass beads are evenly distributed and filled between two opposite surfaces of the first alloy magnetic core and the second alloy magnetic core; the first alloy magnetic core is provided with a first mounting hole for installing the copper sheet winding, and the second alloy magnetic core is provided with a second mounting hole for installing the copper sheet winding;

[0009] The copper sheet winding includes a primary winding composed of two first copper sheets and a secondary winding composed of two second copper sheets. The first copper sheets and the second copper sheets are arranged in parallel, and the two first copper sheets are located between the two second copper sheets; each component is assembled and bonded into an integral body through epoxy resin.

[0010] Preferably, there are four first mounting holes, two of which are arranged in parallel on the left side of the first alloy magnetic core, and the other two are arranged in parallel on the right side of the second alloy magnetic core;

[0011] There are two second mounting holes, one of which corresponds to the two first mounting holes on the left side; the other second mounting hole corresponds to the two first mounting holes on the right side.

[0012] Preferably, the first alloy magnetic core has a "field" - shaped structure; the second alloy magnetic core has a "day" - shaped structure.

[0013] Preferably, the first copper sheet has a "U" - shaped structure.

[0014] Preferably, the second copper sheet includes a U - shaped section and a straight section that is bent horizontally and clamped on the surface of the first alloy magnetic core.

[0015] Preferably, the thickness of the first copper sheet is greater than the thickness of the second copper sheet.

[0016] Preferably, the thickness of the first copper sheet is 0.8 - 1.5 mm, and the thickness of the second copper sheet is 0.5 - 1.2 mm.

[0017] Preferably, the first alloy magnetic core and the second alloy magnetic core adjust the inductance structure through the size of the glass beads and form a closed magnetic field.

[0018] Preferably, the diameter of the glass beads is 0.1 - 0.5 mm.

[0019] Compared with existing technologies, the beneficial effects of this invention are as follows: By employing a first alloy magnetic core and a second alloy magnetic core, and adjusting the inductor structure with intermediate glass beads, a closed magnetic field is formed, improving the magnetic field utilization efficiency and magnetic flux coupling effect of the inductor, thereby enhancing the inductor's performance and power handling capability. The copper sheet windings used, with two first copper sheets as primary windings and two second copper sheets as secondary windings, enable efficient energy transfer and voltage conversion. Simultaneously, the secondary windings can be connected in series according to actual needs, improving the inductor's flexibility and adaptability. Bonding and assembling the alloy magnetic core and copper sheet windings together with epoxy resin improves the inductor's mechanical strength and reliability, while ensuring good insulation performance and preventing electrical short circuits between the windings and the magnetic core. This high-current coupled inductor topology, used in conjunction with a multiphase buck converter, can achieve very fast load transient response with minimal output capacitance. This is because the coupled inductor can achieve rapid energy transfer between different phases, reducing dependence on large-capacity output capacitors and thus improving the system's dynamic performance. By eliminating the output capacitor in traditional circuits, the coupled inductor structure of this invention simplifies circuit design, reduces system cost and size, and increases power density. This is particularly important for portable electronic devices and highly integrated power management modules. Furthermore, the multi-phase voltage-regulated high-current coupled inductor of this invention exhibits excellent fast load transient response capability, effectively suppressing output voltage fluctuations and ensuring stable power output. This has significant application value for high-performance electronic systems with stringent power quality requirements, such as high-speed processors and communication equipment.

[0020] In summary, the high-current coupled inductor provided by this invention, through innovative core structure design and winding configuration combined with epoxy resin bonding technology, achieves a high-efficiency, high-power-density, and fast transient response high-current inductor device. This inductor device can work in conjunction with multiphase buck converters, reducing output capacitor requirements while providing excellent dynamic performance and stability. It is suitable for various high-performance power management applications and has broad market prospects and application value. Attached Figure Description

[0021] Figure 1 This is one of the three-dimensional structural schematic diagrams of this utility model;

[0022] Figure 2 This is the second three-dimensional structural schematic diagram of the present invention;

[0023] Figure 3 This is an exploded view of the structure of this utility model.

[0024] In the diagram: 1. First alloy magnetic core; 2. Second alloy magnetic core; 3. Primary winding; 4. Secondary winding; 5. Glass bead. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] like Figures 1-3 As shown, the present invention provides a high-current coupled inductor, comprising a first alloy magnetic core 1 and a second alloy magnetic core 2 stacked together, and copper sheet windings installed within the first alloy magnetic core 1 and the second alloy magnetic core 2; uniformly distributed glass beads 5 are filled between two opposing surfaces of the first alloy magnetic core 1 and the second alloy magnetic core 2; the first alloy magnetic core 1 is provided with a first mounting hole for installing the copper sheet windings, and the second alloy magnetic core 2 is provided with a second mounting hole for installing the copper sheet windings.

[0027] In this embodiment, the first alloy magnetic core 1 and the second alloy magnetic core 2 adjust the inductance structure and form a closed magnetic field by adjusting the size of the glass beads 5. Preferably, the diameter of the glass beads is 0.1~0.5mm.

[0028] In this process, glass beads 5 are uniformly filled and distributed between the two opposing surfaces of the first alloy magnetic core 1 and the second alloy magnetic core 2, and are fixed by epoxy resin bonding. The glass beads 5 fill the parallel surfaces of the two alloy magnetic cores to ensure that the two magnetic cores maintain a stable spacing and alignment when stacked. This filling method not only fixes the position of the magnetic core, but also provides the necessary mechanical support through the elasticity and hardness of the glass beads, preventing the magnetic core from shifting or vibrating during high current operation.

[0029] The diameter of the glass bead 5 directly affects the spacing between the two alloy magnetic cores, thereby adjusting the magnetic flux path and coupling efficiency of the overall inductor structure. By selecting glass beads 5 of different diameters, the distance between the magnetic cores can be precisely controlled, thus optimizing the magnetic flux coupling effect and improving the inductor's performance. Specifically, larger diameter glass beads 5 increase the magnetic core spacing and reduce the magnetic flux density, suitable for applications requiring a lower coupling coefficient; while smaller diameter glass beads 5 reduce the magnetic core spacing and increase the magnetic flux density, suitable for applications requiring a high coupling coefficient and efficient energy transfer. Therefore, by adjusting the diameter of the glass beads, the inductance value of the product can be met to meet the needs of different voltage regulation circuits. Specifically, glass beads 5 of appropriate size can be selected according to the actual application scenario and bonded and fixed with epoxy resin.

[0030] In this embodiment, the copper sheet winding includes a primary winding 3 composed of two first copper sheets and a secondary winding 4 composed of two second copper sheets. The first copper sheets and the second copper sheets are arranged in parallel, and the two first copper sheets are located between the two second copper sheets; each component is assembled and bonded with epoxy resin to form an integral body.

[0031] In this embodiment, there are four first mounting holes, two of which are arranged in parallel on the left side of the first alloy magnetic core 1, and the other two are arranged in parallel on the right side of the second alloy magnetic core 2; there are two second mounting holes, one of the second mounting holes corresponds to the two first mounting holes on the left side; the other second mounting hole corresponds to the two first mounting holes on the right side.

[0032] In this embodiment, the first alloy magnetic core 1 has a "field" - shaped structure; the second alloy magnetic core 2 has a "sun" - shaped structure. The "field" - shaped structure of the first alloy magnetic core 1 and the "sun" - shaped structure of the second alloy magnetic core 2 not only increase the surface area of the magnetic core, thereby improving the magnetic flux, but also help to achieve a more complex magnetic field path, improving the efficiency and stability of the inductor. And this structural design can make the entire inductor structure more compact and small in volume.

[0033] In this embodiment, the first copper sheet has a "U" - shaped structure; the second copper sheet includes a U - shaped section and a straight section that is bent horizontally and clamped on the surface of the first alloy magnetic core.

[0034] In this embodiment, the thickness of the first copper sheet is greater than that of the second copper sheet. The thickness of the first copper sheet is 0.8 - 1.5 mm, and the thickness of the second copper sheet is 0.5 - 1.2 mm. The two large copper sheets serve as the primary winding of the coupled inductor, and the two small copper sheets serve as the secondary winding of the coupled inductor.

[0035] Compared with the prior art, the utility model adopts a "field" - shaped alloy magnetic core and a "day" - shaped alloy magnetic core, and adjusts the inductance structure by padding glass beads in the middle to form a closed magnetic field, improving the magnetic field utilization efficiency and magnetic flux coupling effect of the inductor, thereby enhancing the performance and power handling capacity of the inductor. The copper - sheet winding adopted, where two first copper sheets serve as the primary winding and two second copper sheets serve as the secondary winding, can achieve efficient energy transfer and voltage transformation. At the same time, the secondary winding can be connected in series according to actual needs, improving the flexibility and adaptability of the inductor. The alloy magnetic core and the copper - sheet winding are bonded and assembled together by epoxy resin, improving the mechanical strength and reliability of the inductor, while ensuring good insulation performance and preventing electrical short - circuit between the winding and the magnetic core. When this high - current coupled inductor topology is used with a multiphase buck converter, it can achieve a very fast load transient response with a minimum output capacitor. The transient response time is reduced from 40 ms of a traditional inductor to 2 - 5 ms. This is because the coupled inductor can achieve rapid energy transfer between different phases, reducing the dependence on a large - capacity output capacitor, thereby improving the dynamic performance of the system. By removing the output capacitor in the traditional circuit, the coupled inductor structure of the utility model can simplify the circuit design, reduce the system cost and volume, and increase the power density, which is particularly important for portable electronic devices and highly integrated power management modules. In addition, the multiphase voltage - regulated high - current coupled inductor of the utility model has excellent fast load transient response ability, which can effectively suppress the fluctuation of the output voltage and ensure a stable power output. This has important application value for high - performance electronic systems with strict requirements for power supply quality, such as high - speed processors and communication devices.

[0036] The embodiments of the utility model are given for purposes of illustration and description, and are not intended to be exhaustive or to limit the utility model to the disclosed form. Many modifications and variations are obvious to those of ordinary skill in the art. The embodiments are chosen and described in order to better illustrate the principles of the utility model and its practical application, and to enable those of ordinary skill in the art to understand the utility model and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A high-current coupled inductor, characterized in that, It includes a first alloy magnetic core and a second alloy magnetic core arranged in a stacked manner, and a copper sheet winding installed in the first alloy magnetic core and the second alloy magnetic core; glass beads are evenly distributed between two opposite surfaces of the first alloy magnetic core and the second alloy magnetic core; the first alloy magnetic core is provided with a first mounting hole for installing the copper sheet winding, and the second alloy magnetic core is provided with a second mounting hole for installing the copper sheet winding; The copper sheet winding includes a primary winding composed of two first copper sheets and a secondary winding composed of two second copper sheets. The first copper sheets and the second copper sheets are arranged in parallel, and the two first copper sheets are located between the two second copper sheets; wherein, each component is assembled and bonded into an integral body by epoxy resin.

2. The high-current coupled inductor according to claim 1, characterized in that: There are four first mounting holes, two of which are arranged in parallel on the left side of the first alloy magnetic core, and the other two are arranged in parallel on the right side of the second alloy magnetic core; There are two second mounting holes, one of the second mounting holes corresponds to the two first mounting holes on the left side; the other second mounting hole corresponds to the two first mounting holes on the right side.

3. The high-current coupled inductor according to claim 1, characterized in that: The first alloy magnetic core has a "field" - shaped structure; the second alloy magnetic core has a "sun" - shaped structure.

4. A high-current coupled inductor according to claim 1, characterized in that: The first copper sheet has a "U" - shaped structure.

5. A high-current coupled inductor according to claim 1, characterized in that: The second copper sheet includes a U - shaped section and a straight section that is bent horizontally and clamped on the surface of the first alloy magnetic core.

6. A high-current coupled inductor according to claim 1, characterized in that: The thickness of the first copper sheet is greater than the thickness of the second copper sheet.

7. A high-current coupled inductor according to claim 6, characterized in that: The thickness of the first copper sheet is 0.8 - 1.5 mm, and the thickness of the second copper sheet is 0.5 - 1.2 mm.

8. A high-current coupled inductor according to claim 1, characterized in that: The first alloy magnetic core and the second alloy magnetic core adjust the inductance structure through the size of the glass beads and form a closed magnetic field.

9. A high-current coupled inductor according to claim 1 or 8, characterized in that: The diameter of the glass beads is 0.1 - 0.5 mm.

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