High-precision high-frequency large-current inductor

Abstract

The utility model provides a high-precision high-frequency large-current inductor. The high-precision high-frequency large-current inductor comprises a magnetic core, a terminal and a magnetic cover, wherein the magnetic core is magnetic; the terminal is conductive; the terminal comprises a first section, a second section and a third section, wherein the second section and the third section are arranged at the two ends of the first section, and the first section, the second section and the third section half surround the magnetic core. The magnetic cover is provided with an accommodating cavity and an opening, the opening is communicated with the accommodating cavity and an external space, the accommodating cavity is used for accommodating the magnetic core and the terminal, and one end, far away from the first section, of the second section and one end, far away from the third section, of the third section are exposed out of the magnetic cover. When the terminal is welded on the PCB, the magnetic cover and the PCB completely enclose the magnetic core, so that the magnetic leakage phenomenon is avoided. Moreover, the magnetic cover has magnetic conductivity, so that the anti-interference capability of the inductor can be enhanced. By implementing the high-precision high-frequency large-current inductor provided by the utility model, an inductor suitable for a server power supply and a GPU (Graphics Processing Unit) can be realized.

Description

Technical Field

[0001] This utility model relates to the field of electronic components, and in particular to a high-precision, high-frequency, high-current inductor. Background Technology

[0002] Server power supplies (such as 48V DC / DC converters) and AI accelerator card power supplies (such as GPU / ASIC power supply modules) place stringent four-dimensional demands on inductors: 1. Ultra-high power density: AI training clusters consume over 50kW per rack, requiring inductor volume to be reduced to less than 60% of traditional designs; 2. Transient response limits: GPU core current change rate (di / dt) reaches 5000A / μs, requiring inductor value fluctuation <±2%; 3. Zero EMC tolerance: Excessive electromagnetic interference (CISPR 32 Class B) within data center racks will cause the entire rack to fail; 4. High-temperature lifespan challenge: A lifespan of 100,000 hours (MTBF > 1e6 hours) must be ensured under 80℃ ambient temperature + self-heating conditions. Transient currents cause saturation, existing power inductors have insufficient DC superposition capability, and GPU voltage ripple >100mV, frequently triggering circuit protection. Existing inductors cannot meet the application requirements of server power supplies and GPUs. Utility Model Content

[0003] To address the shortcomings of existing technologies, this invention provides a high-precision, high-frequency, high-current inductor, making it suitable for server power supplies and GPUs.

[0004] Therefore, one embodiment provides a high-precision, high-frequency, high-current inductor, comprising:

[0005] A magnetic core is magnetic.

[0006] A terminal, having conductivity, includes a first segment and a second and a third segment disposed at both ends of the first segment, the first segment, the second segment and the third segment partially surrounding the magnetic core;

[0007] A magnetic shield with magnetic permeability has a receiving cavity and an opening, the opening connecting the receiving cavity to an external space, the receiving cavity for receiving the magnetic core and the terminal, and the ends of the second segment and the third segment away from the first segment are exposed in the magnetic shield.

[0008] As a further alternative to the high-precision high-frequency high-current inductor, the first segment is provided with at least two positioning holes, and the magnetic core is provided with positioning bosses corresponding to the positioning holes.

[0009] As a further alternative to the high-precision, high-frequency, high-current inductor, the receiving cavity is provided with a sliding groove, and the second segment and / or the third segment can be inserted into the sliding groove in the width direction.

[0010] As a further alternative to the high-precision high-frequency high-current inductor, the second segment and the third segment are provided with pins at the ends away from the first segment, and the magnetic cover is provided with positioning points corresponding to the opening, the positioning points being used to position the pins.

[0011] As a further alternative to the high-precision, high-frequency, high-current inductor, the pin has a pin slot, and the positioning point is located at the pin slot.

[0012] As a further alternative to the high-precision, high-frequency, high-current inductor, the magnetic shield has a permeability of 900–3300 μI.

[0013] As a further alternative to the high-precision, high-frequency, high-current inductor, the magnetic shield is made of one of the following materials: Mn-Zn ferrite, Ni-Zn ferrite, or amorphous nanocrystalline material.

[0014] As a further alternative to the high-precision, high-frequency, high-current inductor, the terminals are plated with nickel or tin.

[0015] As a further alternative to the high-precision, high-frequency, high-current inductor, the BS value of the magnetic core is 1.0 to 1.6T.

[0016] As a further alternative to the high-precision, high-frequency, high-current inductor, the portion of the magnetic core extending out of the receiving cavity is coplanar with the outer wall surface of the magnetic shield.

[0017] Implementing the embodiments of this utility model will have the following beneficial effects:

[0018] Based on the high-precision, high-frequency, high-current inductor in the above embodiments, the terminals are generally strip-shaped, formed by two bends to create the first, second, and third segments. The terminals partially surround the magnetic core, and then the terminals and magnetic core are placed together into a receiving cavity within a magnetic shield. When the terminals are soldered onto the PCB board, the magnetic shield and PCB board completely enclose the magnetic core, thus preventing magnetic leakage. Furthermore, the magnetic shield's magnetic permeability enhances the inductor's anti-interference capability. Implementing the high-precision, high-frequency, high-current inductor of this invention can realize an inductor suitable for server power supplies and GPUs. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] in:

[0021] Figure 1 A schematic diagram of the overall structure of a high-precision, high-frequency, high-current inductor according to an embodiment of the present invention is shown.

[0022] Figure 2 A schematic diagram of the structure of a magnetic shield according to an embodiment of the present invention is shown;

[0023] Figure 3 A schematic diagram of the overall structure of a terminal according to an embodiment of the present invention is shown;

[0024] Figure 4 A schematic diagram of the overall structure of a magnetic core according to an embodiment of the present invention is shown;

[0025] Figure 5 An assembly diagram of the magnetic core and terminals provided according to an embodiment of the present invention is shown.

[0026] Explanation of key component symbols:

[0027] Magnetic core-10; Terminal-20; First section-210; Second section-220; Third section-230; Magnetic cover-30; Receiving cavity-310; Opening-320; Positioning hole-2110; Positioning boss-110; Slide groove-3110; Pin-240; Positioning point-330; Pin slot-241. Detailed Implementation

[0028] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0029] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] This utility model provides a high-precision, high-frequency, high-current inductor. Please refer to [reference needed]. Figures 1-5 The high-precision, high-frequency, high-current inductor includes a magnetic core 10, conductive terminals 20, and a magnetic shield 30. Terminal 20 includes a first segment 210 and second segments 220 and third segments 230 disposed at both ends of the first segment 210, with the first, second, and third segments 230 partially surrounding the magnetic core 10. The magnetic shield 30 has a receiving cavity 310 and an opening 320, the opening 320 connecting the receiving cavity 310 to an external space. The receiving cavity 310 is used to house the magnetic core 10 and the terminals 20, and the ends of the second and third segments 220 furthest from the first segment 210 are exposed outside the magnetic shield 30.

[0032] Based on the high-precision, high-frequency, high-current inductor in the above embodiments, the terminal 20 is generally strip-shaped, formed by two bends to create a first segment 210, a second segment 220, and a third segment 230. The terminal 20 partially surrounds the magnetic core 10, and then the terminal 20 and the magnetic core 10 are placed together into the receiving cavity 310 in the magnetic cover 30. When the terminal 20 is soldered onto the PCB board, the magnetic cover 30 and the PCB board completely enclose the magnetic core 10, thereby avoiding magnetic leakage. Furthermore, the magnetic cover 30 has magnetic permeability, which can enhance the inductor's anti-interference capability. Implementing the high-precision, high-frequency, high-current inductor of this invention can realize an inductor suitable for server power supplies and GPUs.

[0033] Terminal 20 is strip-shaped, providing high strength and improving service life in high-temperature environments. The overall structure of the inductor has almost no gaps, making it the smallest inductor with equivalent performance.

[0034] In some specific embodiments, the first segment 210 is provided with at least two positioning holes 2110, and the magnetic core 10 is provided with positioning bosses 110 corresponding to the positioning holes 2110.

[0035] By adapting the positioning boss 110 and the positioning hole 2110, the positions of the magnetic core 10 and the terminal 20 are kept consistent across batches. This arrangement ensures that the basic parameter values ​​of inductors produced in batches are close to or identical.

[0036] Generally, the magnetic core 10 and the terminal 20 are surface-mounted to prevent the magnetic core 10 from shaking during use.

[0037] In some specific embodiments, the receiving cavity 310 is provided with a groove 3110, and the second segment 220 and / or the third segment 230 can be inserted into the groove 3110 in the width direction.

[0038] In this embodiment, the widths of the second segment 220 and the third segment 230 are wider than the width of the first segment 210. When the terminal 20 and the magnetic core 10 are inserted together into the magnetic cover 30, the second segment 220 and the third segment 230 are inserted into the slide groove 3110. Generally, the width of the slide groove 3110 is slightly wider than the widths of the second segment 220 and the third segment 230, so that the terminal 20 and the magnetic cover 30 can be relatively fixed after assembly, thereby maintaining the consistency of the overall performance of the inductor.

[0039] Specifically, it mainly restricts the swaying of terminal 20 relative to magnetic cover 30 along the length of magnetic cover 30. Only one of the second segment 220 and the third segment 230 needs to be inserted into the slide groove 3110 to provide relative fixation. Generally, the third segment 230 and the second segment 220 are symmetrically arranged relative to the first segment 210, so usually both the second segment 220 and the third segment 230 need to be inserted into their respective slide grooves 3110.

[0040] In some specific embodiments, the second segment 220 and the third segment 230 are provided with pins 240 at the ends away from the first segment 210, and the magnetic cover 30 is provided with positioning points 330 at the opening 320, which are used to position the pins 240.

[0041] The pin 240 is positioned to facilitate subsequent soldering, allowing the inductor in this invention to be mounted on the GPU or power supply circuit. The positioning point 330 is positioned to further ensure the consistency of the pin 240, meaning that the pin 240 positions of mass-produced inductors are basically consistent, thereby facilitating subsequent automated soldering operations on the pin 240.

[0042] Specifically, the method of matching the positioning point 330 and the pin 240 includes having a groove on the pin 240 that matches the positioning point 330. Alternatively, the shape of the opposite side of the positioning point 330 and the pin 240 may match.

[0043] It should be noted that pins 240 generally extend from the opening 320 to facilitate subsequent soldering processes. The magnetic shield 30 has a notch corresponding to pins 240 to further restrict the movement of pins 240 in the width direction of the magnetic shield 30. The positioning point 330 is generally located at the notch.

[0044] In some specific embodiments, pin 240 has pin slot 241, and positioning point 330 is located at pin slot 241.

[0045] The pin slot 241 serves two main purposes: firstly, it limits the wobble of the terminal 20 relative to the magnetic cover 30 in the width direction of the magnetic cover 30. Secondly, the pin slot 241 provides the inductor with a larger soldering area during the soldering process, ensuring a strong solder joint and improving the inductor's impact resistance and mechanical strength, among other things.

[0046] The pin slot 241 can be rectangular, circular, or U-shaped.

[0047] In some specific embodiments, the magnetic permeability of the magnetic shield 30 is 900 to 3300 μI.

[0048] Magnetic permeability is a physical quantity that measures the magnetic conductivity of an object and is an inherent characteristic of a magnetic circuit. Once a magnetic circuit is fixed, its magnetic permeability is a fixed value under the same environment. The magnetic cover 30 is made of a material with a magnetic permeability of 900-3000 μI and is integrally formed by sintering, thus ensuring the consistency of the parameters of the magnetic cover 30. Correspondingly, the magnetic cover 30 restricts the position of the terminal 20 due to structures such as the oil notch, the groove 3110, and the positioning point 330. The terminal 20, in turn, restricts the position of the magnetic core 10, ultimately ensuring the consistency of the performance of the produced inductors. The main function of the magnetic cover 30 is to provide shielding and improve the inductor's anti-interference capability. The shape of the magnetic cover 30 can be cubic, spherical, or polyhedral.

[0049] In some specific embodiments, the magnetic shield 30 is made of one of the following materials: Mn-Zn ferrite, Ni-Zn ferrite, or amorphous nanocrystalline material.

[0050] Characteristics of Mn-Zn ferrite: Mn-Zn ferrite is known for its high permeability, with a high initial permeability typically around 3000. This material also has a relatively high saturation magnetic flux density, generally around 0.5T. However, its resistivity is relatively low, approximately 5.0 Ω·m, resulting in relatively high losses in high-frequency applications.

[0051] Applications: Due to its high permeability and good low-frequency performance, Mn-Zn ferrite is suitable for power inductors, transformers, and common-mode chokes ranging from tens of kHz to MHz. For example, in switching power supplies, Mn-Zn ferrite cores can be used to fabricate high-current inductors for efficient energy conversion.

[0052] Characteristics of Ni-Zn ferrite: Ni-Zn ferrite has a very high resistivity, reaching 10 Ω·cm. 5 -10 8 Its low permeability (Ω·m) results in lower losses in high-frequency applications. Its initial permeability is relatively low compared to Mn-Zn ferrites, typically between 500 and 1500, but its performance advantages become increasingly apparent as the frequency increases.

[0053] Applications: Ni-Zn ferrites are particularly suitable for high-frequency (MHz to GHz) electromagnetic interference suppression and radio frequency (RF) circuits. For example, in RFID systems, Ni-Zn ferrite magnetic rings can be used to fabricate high-frequency antennas to improve signal transmission efficiency.

[0054] Characteristics of amorphous and nanocrystalline materials: Amorphous and nanocrystalline materials have extremely high magnetic permeability, typically greater than 100,000, which makes them excellent for high-power applications. They also have high saturation magnetic flux density, approximately 1.25T, and low losses, making them suitable for low-frequency, high-current applications.

[0055] Application Scenarios: Amorphous and nanocrystalline materials are widely used in common-mode chokes and EMI filters. For example, in electric vehicle inverters, amorphous and nanocrystalline magnetic cores can be used to fabricate common-mode inductors for EMC circuits. Their high permeability and saturation flux density effectively suppress common-mode interference.

[0056] Each of these three materials has its advantages, and the choice of which material to use depends on the specific application scenario of the magnetic cover 30. If the application scenario mainly involves low frequency and requires high permeability, amorphous nanocrystals are a good choice; if the application scenario involves high frequency and requires low loss, Ni-Zn ferrite or Mn-Zn materials may be more suitable.

[0057] In some specific embodiments, terminal 20 is plated with nickel or tin.

[0058] In this embodiment, the terminal 20 can be a flat enameled wire, or it can be a stamped or cut metal part that has been electroplated. Nickel and tin are both conductive materials with excellent conductivity and strong oxidation resistance, making them resistant to corrosion, oxidation, and moisture. Nickel and tin also have high solderability, which can aid in the subsequent inductor soldering process.

[0059] In some specific embodiments, the BS value of the magnetic core 10 is 1.0 to 1.6T.

[0060] The BS value of core 10 refers to the saturation magnetic induction of the core 10 material, measured in Tesla (T). When the magnetic induction of core 10 reaches the BS value, the magnetization of the material reaches saturation, meaning the magnetic flux density no longer increases significantly with the increase of the applied magnetic field. A BS value of 1.0–1.6T for core 10 can achieve better DC bias capability and a more stable temperature coefficient. The DC bias capability of an inductor refers to the characteristic of its inductance changing with the applied DC current. Specifically, when a DC current flows through the inductor, the magnetization state of core 10 changes, causing the inductance to decrease.

[0061] The magnetic core 10 can be made of materials such as iron-nickel alloy, iron-silicon-aluminum, iron-silicon, iron-silicon-nickel, and amorphous nanocrystalline materials. Different magnetic cores 10 can be designed according to different application scenarios to achieve different electrical performances. The magnetic core 10 is generally rectangular, and its length, width, and height can be adjusted as needed.

[0062] For example, the DC bias capability of an inductor refers to the characteristic of its inductance changing with the DC current when a DC current is applied. Specifically, when a DC current flows through the inductor, the magnetization state of the magnetic core 10 changes, causing the inductance to decrease.

[0063] In some specific embodiments, the portion of the magnetic core 10 extending out of the receiving cavity 310 is coplanar with the outer wall surface of the magnetic cover 30.

[0064] The magnetic core 10 does not fall entirely into the receiving cavity 310. After the magnetic core 10 is inserted into the magnetic cover 30, the outer wall surface of the magnetic core 10 and the magnetic cover 30 are coplanar. Therefore, when the inductor is soldered, the magnetic core 10 can be fixed through the PCB board and the magnetic core 10 is completely sealed.

[0065] Finally, it should be noted that the inductors in the power supplies of GPUs and servers are components. The overall size of the inductor is very small, and even slight errors in the assembly of the magnetic core 10, terminal 20, and magnetic shield 30 can significantly alter the inductor's performance parameters. Through the structural design of the magnetic core 10, terminal 20, and magnetic shield 30, the assembled inductor's performance accuracy and the spacing between the magnet and the magnetic shield 30 are made as consistent as possible.

[0066] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0067] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A high-precision, high-frequency, high-current inductor, characterized in that, include: A magnetic core is magnetic. A terminal, having conductivity, includes a first segment and a second and a third segment disposed at both ends of the first segment, the first segment, the second segment and the third segment partially surrounding the magnetic core; A magnetic shield with magnetic permeability has a receiving cavity and an opening, the opening connecting the receiving cavity to an external space, the receiving cavity for receiving the magnetic core and the terminal, and the ends of the second segment and the third segment away from the first segment are exposed in the magnetic shield.

2. The high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The first segment is provided with at least two positioning holes, and the magnetic core is provided with positioning bosses corresponding to the positioning holes.

3. The high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The receiving cavity is provided with a sliding groove, and the second section and / or the third section can be inserted into the sliding groove in the width direction.

4. The high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The second segment and the third segment are provided with pins at the ends away from the first segment, and the magnetic cover is provided with positioning points corresponding to the opening, the positioning points being used to position the pins.

5. A high-precision, high-frequency, high-current inductor as described in claim 4, characterized in that, The pin has a pin slot, and the positioning point is located at the pin slot.

6. A high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The magnetic permeability of the magnetic shield is 900–3300 μI.

7. A high-precision, high-frequency, high-current inductor as described in claim 6, characterized in that, The magnetic shield is made of one of the following materials: Mn-Zn ferrite, Ni-Zn ferrite, or amorphous nanocrystalline material.

8. A high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The terminals are plated with nickel or tin.

9. A high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The BS value of the magnetic core is 1.0 to 1.6T.

10. A high-precision, high-frequency, high-current inductor as described in claim 1, characterized in that, The portion of the magnetic core extending out of the receiving cavity is coplanar with the outer wall surface of the magnetic shield.

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