Integrally-formed and partially-coupled TLVR inductor

Abstract

The utility model discloses an integrally-formed and partially-coupled TLVR inductor which is formed by combining a preformed T-shaped magnetic core, a concave table magnetic core, a primary coil and a secondary coil, the T-shaped magnetic core is provided with a sheet body part with a rectangular main body and a first protruding part formed by extending one side of the sheet body part; the concave table magnetic core is provided with a containing groove with the outer contour consistent with that of the sheet body part and a second protruding part formed by extending of the inner wall of the containing groove. The primary coil is formed into a U shape, the inner side of the bottom of the primary coil wraps the first protruding part, the secondary coil is formed into a C shape wrapping the second protruding part, the secondary coil and the second protruding part are integrally located in the remaining space of the inner side of the primary coil, and two magnetic cores loaded with the coils are spliced in an edging mode and packaged into a whole in a hot pressing mode. According to the TLVR inductor, a part of leakage inductance generated by coupling of primary and secondary coils is reduced, and the mutual coupling coefficient klt in the inductor is reduced; moreover, the overall height of the TLVR inductor does not need to be increased, an additional inductor Lc does not need to be connected in series in circuit application, and the cost and the occupied space of a main polar plate can be reduced at the same time.

Description

TECHNICAL FIELD

[0001] The utility model relates to an inductor device especially to a TLVR inductor which is integrally formed and has two coil parts coupled in it 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 increasing 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 winding with two pins, while the TLVR inductor has two sets of winding with controllable and adjustable coupling rate and four pins. There is a great difference in structure between the two.

[0004] Currently, in the industry, in addition to the main goal of coupling efficiency between two coils in the structural design of TLVR inductors, the number of components and the occupied space in high-density PCBs are also the focus of attention. Therefore, the organic integration of TLVR inductors in limited space has become a technical gap that needs to be filled in the industry. SUMMARY

[0005] In view of the shortcomings of the prior art, the utility model is committed to improving the performance of inductor devices and optimizing the occupied space of components in high-density PCBs.

[0006] The technical solutions of the utility model realize the above-mentioned purposes: the TLVR inductor which is integrally formed and partially coupled is composed of a T-shaped magnetic core, a concave platform magnetic core, a primary coil and a secondary coil, the T-shaped magnetic core is provided with a plate body part with a rectangular main body and a first protruding part which is integrally formed on one side of the plate body part, the concave platform magnetic core is provided with a container groove with an identical outer contour as the plate body part and a second protruding part which is integrally formed on the inner wall of the container groove, the primary coil is integrally formed in a U shape and wraps the first protruding part on the inner side of the bottom, the secondary coil is integrally formed in a C shape which wraps the second protruding part and falls into the remaining space on the inner side of the primary coil together with the second protruding part, and the T-shaped magnetic core and the concave platform magnetic core which load the coils respectively are edge-aligned and spliced and are integrally formed by hot-press packaging.

[0007] Further, the extension heights of the first protruding part and the second protruding part are greater than the widths of the two coils, and in the spliced state of the two magnetic cores, the first protruding part and the second protruding part are seamlessly attached to the inner walls of the opposite magnetic cores.

[0008] Further, the top edge of the plate body part is integrally formed with a raised section corresponding to the width of the first protruding part, the exposed shape of the second protruding part relative to the container groove is identical to the raised section, and the outer contours of the two magnetic cores in the spliced state are coincident in the side view.

[0009] Further, the primary coil is formed by bending and insulating processing of a flat copper strip, and the two free ends of the primary coil extend in opposite directions by a width of an electrode pad.

[0010] Further, the secondary coil is formed by bending of a flat enameled wire, and the two free ends of the secondary coil extend in opposite directions by a width of an electrode pad.

[0011] Further, the T-shaped magnetic core and the concave platform magnetic core are both cold-pressed formed bodies based on customized molds by powder materials.

[0012] Further, the combination of the two magnetic cores and the two coils is filled and permeated with the formed powder material corresponding to the magnetic cores in the hot-press forming mold, and the inductance mounting surface of the hot-press packaging formed body is flush with the outward end faces of the two coils.

[0013] Further, the hot-press packaging formed body is provided with an insulating paint which wraps the entire width, and the electrode pads which are formed by stripping and electroplating are arranged at the positions corresponding to the coils on the inductance mounting surface.

[0014] Compared with the prior art, the application of the TLVR inductor has the advantages that by optimizing the prefabricated shapes and assembly structures of the two-stage magnetic cores and coils, on the one hand, the product assembly stability and manufacturing consistency are ensured, which helps to reduce the space occupied by the inductor in the high-density PCB and the interference influence on the periphery, and on the other hand, it helps to reduce a part of leakage inductance generated by the primary and secondary coil coupling, the internal mutual coupling coefficient k of the inductor is less than 0.75, and without increasing the overall height of the TLVR inductor, no additional inductor Lc needs to be connected in series in the circuit application, which can reduce the cost and the space occupied by the main plate. From the perspective of device application, the operation environment of the circuit can be further improved, and the hardware performance development in the application scenarios of artificial intelligence AI server / data center / automatic driving and smart city transportation is promoted. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a close-up structure schematic view of a T-shaped magnetic core in a preferred embodiment of the TLVR inductor of the present application.

[0016] Figure 2 is a close-up structure schematic view of a primary coil in a preferred embodiment of the TLVR inductor of the present application.

[0017] Figure 3 is a close-up structure schematic view of a recessed magnetic core in a preferred embodiment of the TLVR inductor of the present application.

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

[0019] Figure 5 is an outline evolution schematic view of the assembly and manufacturing of a preferred embodiment of the TLVR inductor of the present application. DETAILED DESCRIPTION

[0020] In order to enable the personnel in the technical field to better understand the present application scheme, the technical solutions in the present application embodiments will be described clearly and completely below in combination with the drawings in the present application embodiments.

[0021] The present application proposes a one-piece and partially coupled TLVR inductor, which is dedicated to improving the performance of inductor devices and optimizing the space occupied by components in high-density PCB. Figures 1 to 5As shown, the TLVR inductor is assembled by pre-molding one T-shaped magnetic core 1, one concave magnetic core 2, one primary coil 3 and one secondary coil 4, and obtained by a series of process technologies such as hot-press packaging, paint spraying, paint stripping and electroplating. In summary, the T-shaped magnetic core 1 is provided with a sheet body part 11 with a rectangular main body and a first protruding part 12 extending from one side of the sheet body part 11. As shown in the figure, the first protruding part 12 is slightly lower, that is, the position of the finished inductor is close to the top after installation in the circuit application. The concave magnetic core 2 is provided with a container groove 12 with the same contour as the sheet body part 11 and a second protruding part 22 extending from the inner wall of the container groove 12. As shown in the figure, the second protruding part 22 is close to the top, that is, the position of the finished inductor is close to the circuit board after installation in the circuit application. The primary coil 3 is shaped like a U and its bottom inner side wraps the first protruding part 12 in the assembled state; and the secondary coil 4 is shaped like a C wrapping the second protruding part 22 and falls into the remaining space on the inner side of the primary coil 3. It can be understood that: the secondary coil is embedded in the primary coil, and the top of the two is separated by the first protruding part, and the two-stage coil is embedded in the container groove as a whole and wraps the second protruding part therein. On the basis of the pre-assembly of the two magnetic cores and the corresponding coils, the two-part semi-finished assembly is edge-aligned and spliced, and then hot-pressed into one body by using special packaging equipment and customized molds. As the basis for the inductor to access the PCB, the exposed parts of the two ends of the coil need to be stripped and electroplated after hot-press packaging and paint spraying, so as to be provided as electrode pads.

[0022] On the basis of the summary of the technical scheme and the preferred embodiment, the details of the TLVR inductor include: the T-shaped magnetic core and the concave magnetic core are both cold-pressed into shape by powder material based on customized molds. The first protruding part 12, the second protruding part 22 and the frame of the container groove are all set at the same height, and the extension height h is greater than the width of the two coils. In the spliced state of the two magnetic cores, the first protruding part 12 is seamlessly attached to the bottom wall of the container groove, and the second protruding part 22 is seamlessly attached to the sheet body part. The two-stage coil is clamped in the slot-shaped cavity formed by the two, and a plurality of fine gaps are left for filling the filler. The combination of the two magnetic cores and the two coils 5 is filled and permeated with the molding powder material corresponding to the magnetic cores in the hot-pressing molding mold, and the inductor mounting surface 61 of the hot-pressing packaging body 6 is flush with the outward-facing end surface 34 of the two coils.

[0023] For example Figure 1 As shown, the top edge of the sheet body part 11 is shaped with a raised section 111 corresponding to the width of the first protruding part, so as to adapt to the gap caused by the bending of the end of the two-stage coil relative to the edge of the container groove. Correspondingly, the exposed shape of the second protruding part relative to the container groove is the same as the raised section, thereby satisfying the outline coincidence of the side view angle in the edge-aligned spliced state of the two magnetic cores.

[0024] Furthermore, the primary coil 3 is formed by bending and insulating a flat copper strip, with its two free ends 31 extending in opposite directions by the width of an electrode pad. Simultaneously, the secondary coil 4 is formed by bending a flat enameled wire, with its two free ends 41 extending in opposite directions by the width of an electrode pad. This allows the two coils to form four linearly arranged and spaced-apart external terminals, facilitating the subsequent fabrication process to create high-strength, isolated electrode pads.

[0025] like Figure 5 As shown in the diagram, the complete manufacturing process of this multi-unit integrated TLVR inductor is as follows: First, T-shaped magnetic cores, recessed magnetic cores, primary coils, and secondary coils are prefabricated in the required proportions. Then, the primary coil 3 is pre-assembled with the T-shaped magnetic core 1 to obtain a semi-finished assembly. However, it should be noted that the assembly strength is relatively weak, with only the first protrusion hooking into the primary coil. Synchronously or asynchronously, the secondary coil 4 is pre-assembled with the recessed magnetic core 2, so that it holds the second protrusion and prevents it from falling off, to obtain another semi-finished assembly. Next, the two semi-finished assemblies are joined together at the edges to form a composite body 5. Then, the composite body 5 is transferred into a customized thermoforming mold with the coil end face facing upwards, and powder is filled in until it completely covers the composite body. It is then molded at a molding pressure of 4-12 Tons / cm² and a temperature of 100-200°C for 30-180 seconds to obtain a thermo-pressed encapsulated body 6 (a common technique in this field, details omitted). After cooling, the thermo-pressed encapsulated body undergoes a roller spraying process to coat its entire surface with an insulating varnish film 7. Then, partial varnish stripping is performed, exposing but not interconnected external contact points at both ends of the primary and secondary coils. Finally, electroplating yields four electrode pads 9 distributed on the same side, thus forming the finished TLVR inductor 8.

[0026] The aforementioned T-shaped magnetic cores and concave magnetic cores are both prefabricated assemblies based on powder materials and customized molds, specifically using a cold pressing molding process. The powder material used for the magnetic core can be one or more mixtures of Fe-based / FeSiCr / FeSiAl / FeNi / amorphous / nanocrystalline materials, and one of epoxy resin, silicone resin, or acrylic resin is added and stirred evenly before being injected into a prefabricated mold that conforms to the shape of the device. The molding pressure range is 6-10 Tons / cm².

[0027] In summary, the preferred embodiment of the integrally molded and partially coupled TLVR inductor of this utility model, as detailed above, demonstrates the following technical advantages compared to existing technologies: By optimizing the prefabricated shape and assembly structure of the two-stage magnetic core and coil, product assembly stability and manufacturing consistency are ensured, helping to reduce the space occupied by the inductor in high-density PCBs and its interference to the surrounding environment. Furthermore, it helps to reduce some of the leakage inductance generated by the coupling of the primary and secondary coils. Maxwell device simulation tests show that the coupling coefficient k of this partially coupled TLVR inductor is only 0.514850, and there is no need to increase the overall height of the TLVR inductor. In circuit applications, there is also no need to connect an additional inductor Lc in series, simultaneously reducing cost and the occupied space of the main plate. From a device application perspective, it can further improve the circuit operating environment and promote the development of hardware performance in application scenarios such as AI servers / data centers / autonomous driving, and smart city transportation.

[0028] 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. An integrally formed and partially coupled TLVR inductor, characterized by: The TLVR inductor is composed of a pre-formed T-shaped magnetic core, a concave platform magnetic core, a primary coil and a secondary coil, the T-shaped magnetic core is provided with a plate body part with a rectangular main body and a first protruding part extended from one side of the plate body part, the concave platform magnetic core is provided with a containing groove with the same outline as the plate body part and a second protruding part extended from the inner wall of the containing groove, the primary coil is shaped as a U-shaped and the bottom inside is wrapped with the first protruding part, the secondary coil is shaped as a C-shaped wrapped with the second protruding part and the whole of the second protruding part is located in the remaining space inside the primary coil, the T-shaped magnetic core and the concave platform magnetic core with the respective coils are edge-aligned and spliced and hot-pressed and packaged into one body.

2. The one-piece, partially-coupled TLVR inductor of claim 1, wherein: The extension height of the first protruding part and the second protruding part is greater than the width of the two coils, and in the spliced state of the two magnetic cores, the first protruding part and the second protruding part are seamlessly attached to the inner wall of the opposite magnetic core.

3. The one-piece, partially-coupled TLVR inductor of claim 1, wherein: The top edge of the plate body part is shaped with a raised section corresponding to the width of the first protruding part, the exposed shape of the second protruding part relative to the containing groove is the same as the raised section, and the outer contours of the two magnetic cores in the spliced state are coincident in the side view.

4. The one-piece, partially-coupled TLVR inductor of claim 1, wherein: The primary coil is shaped by bending and insulating treatment of a flat copper strip, and the two free ends of the primary coil extend in opposite directions by a width of an electrode pad.

5. The one-piece, partially-coupled TLVR inductor of claim 1, wherein: The secondary coil is shaped by bending a flat enameled wire, and the two free ends of the secondary coil extend in opposite directions by a width of an electrode pad.

6. The one-piece, partially-coupled TLVR inductor of claim 1, wherein: The T-shaped magnetic core and the concave platform magnetic core are both cold-pressed and formed by powder material based on customized mold.

7. The one-piece, partially-coupled TLVR inductor of claim 1, wherein: The combination of the two magnetic cores and the two coils is filled and penetrated with the formed powder material corresponding to the magnetic cores in the hot-pressing forming mold, and the inductance mounting surface of the hot-pressing packaging formed body is flush with the outward end faces of the two coils.

8. The one-piece, partially-coupled TLVR inductor of claim 7, wherein: The hot-pressing packaging formed body is provided with an insulating paint wrapped in the full width, and electrode pads are formed by stripping and plating at the positions corresponding to the coils on the inductance mounting surface.

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