Combined coupling inductor

Abstract

The utility model discloses a combined coupling inductor which is formed by assembling a prefabricated secondary coil, more than two primary coils and a pair of magnetic cores which are oppositely spliced into a square body, the surface of one side of at least one magnetic core is flat, and the surface of the other side of at least one magnetic core is provided with a plurality of protruding parts which are arranged in parallel at intervals. The primary coils are continuously bent into a shape like a Chinese character'yu 'in side view and are sleeved on the lug bosses one by one to form two primary inductors which are arranged side by side in a non-contact manner and are mutually coupled, the secondary coils wrap all the primary coils and are attached to the inner walls of the magnetic cores to form secondary inductors coupled with the primary inductors, and the two magnetic cores are bonded into a whole in an edging manner. And all the primary coils and the secondary coils are formed into a plurality of electrode bonding pads which are distributed in a staggered manner on one side surface of the assembly. The inductor is favorable for reducing the occupied space and the interference influence on the periphery, has the characteristics of high coupling efficiency, good coplanarity, good size consistency and the like, and is suitable for a high-density and quick-response power supply module system.

Description

Technical Field

[0001] This utility model relates to an inductor device, and more particularly to a combined coupled inductor for TLVR architecture, belonging to the field of basic electronic components technology. Background Technology

[0002] Inductors are one of the most commonly used components in electronic devices, widely used in various circuits to perform functions such as filtering, energy storage, matching, and resonance. With the increasing miniaturization and portability of electronic products, and the high-density assembly of components, inductor components have developed rapidly. Furthermore, considering electromagnetic compatibility, the ability of electronic products to resist electromagnetic interference has become a basic design requirement, thus increasing the demand for and application of inductors.

[0003] As edge devices such as AI servers and high-speed computing units increasingly demand higher power supply stability and dynamic response speed, traditional multiphase power supplies face challenges in terms of space constraints and functional density. To address switching losses and output filter size issues under high-frequency loads, the industry is gradually adopting the TLVR architecture, which utilizes coupled inductors to connect phases in series to improve instantaneous response.

[0004] However, existing multiphase TLVR architecture inductors are mostly designed by assembling the primary coil, secondary coil, and magnetic core into a single phase, which suffers from complex structure, unstable coupling coefficients, and requires a large design space. Furthermore, there are shortcomings in product consistency and automated manufacturing processes. Therefore, the integration of multiple TLVR inductors within a limited space and the optimization of coupling coefficients have become a crucial technological gap that urgently needs to be filled in the industry. Summary of the Invention

[0005] The purpose of this invention is to propose a combined coupling inductor, which aims to improve the performance of inductor devices and optimize the space occupied by components in high-density PCBs.

[0006] The technical solution of this utility model to achieve the above-mentioned objective is: a combined coupled inductor, characterized in that: the inductor is assembled from a pre-fabricated secondary coil, two or more primary coils and a pair of magnetic cores spliced ​​together to form a block, at least one magnetic core has a flat surface on one side and a plurality of parallel and spaced protrusions on the other side surface, the primary coils are continuously bent into a side view U-shape and are paired and connected to the protrusions to form two non-contact parallel and mutually coupled primary inductors, the secondary coils wrap around all the primary coils and are attached to the inner wall of the magnetic cores to form secondary inductors coupled to each primary inductor, the two magnetic cores are bonded together with flush edges, and all the primary coils and secondary coils are formed into a plurality of staggered electrode pads on one side of the assembly.

[0007] Furthermore, the magnetic cores are formed into a pair with the same shape, one of the magnetic cores having a pair of sidewalls that clamp the protrusions. The protrusions are arranged at equal intervals, and the top of the protrusion is recessed relative to the top surface of the magnetic core by a distance greater than the sum of the thicknesses of the two coils, and the bottom of the protrusion is flush with the bottom surface of the magnetic core. When the pair of magnetic cores are assembled, the sidewalls are assembled into a pair of sidewalls, and the inner protrusions are aligned and assembled into the inner core of the coil.

[0008] Furthermore, the magnetic cores are formed as a pair with the same shape. One of the magnetic cores has a U-shaped convex edge that clamps the protrusion. The protrusions are arranged at equal intervals in pairs. The top of the protrusion is recessed relative to the inner wall of the top side of the U-shaped convex edge by a distance greater than the sum of the thicknesses of the two coils. The bottom of the protrusion is recessed relative to the bottom end face of the U-shaped convex edge by a distance matching the thickness of the secondary coil. When the pair of magnetic cores are assembled, the U-shaped convex edges are assembled into a top wall and a pair of side walls, and the inner protrusions are aligned and assembled into the inner core of the coil.

[0009] Furthermore, the magnetic cores are formed into a pair with different shapes and flush edges. The first magnetic core is a square sheet, and the second magnetic core is a double-sided open cube enclosing equally spaced protrusions. The gap between the top of the protrusion and the inner wall of the top side of the second magnetic core is greater than the sum of the thicknesses of the two coils. The bottom of the protrusion is recessed relative to the bottom surface of the second magnetic core by a distance matching the thickness of the secondary coil. The first magnetic core is attached to the second magnetic core and flush edges are joined together.

[0010] Furthermore, the primary coil is an embedded accessory formed by cutting and continuously bending a flat copper strip, and the surface of the primary coil is coated with an epoxy resin insulating layer; the width of the flat copper strip is less than the length of the protrusion after assembly, and both ends of the flat copper strip are bent downward from the top side of the protrusion and extend obliquely toward the adjacent magnetic core in opposite directions until they are bent relative to each other at the bottom side of the protrusion to wrap around the protrusion.

[0011] Furthermore, the secondary coil is an inlay fitting made of flat copper sheet with insulating enamel coating, cut and continuously bent into a U-shape. The width of the flat copper sheet is consistent with the length of the protrusion after assembly. The inner width of the secondary coil is greater than the sum of the outer widths of several primary coils contained therein. The two ends of the secondary coil are bent outward and attached to the bottom side of the magnetic core.

[0012] Furthermore, the magnetic core has three parallel and spaced protrusions, and each protrusion is fitted with a primary coil. The secondary coil wraps around all the primary coils and is attached to the inner wall of the magnetic core.

[0013] Furthermore, the magnetic core is a cold-pressed molded body made of powder material based on a customized mold, and the two magnetic cores in pairs and their protrusions are distributed and glued together and cold-pressed into one piece or directly assembled and hot-pressed into one piece.

[0014] Compared with existing technologies, the advantages of this inductor are as follows: By optimizing the prefabricated shape of the core and the two-stage coils with a one-to-many nesting configuration, the assembly structure is improved, which helps reduce the space occupied by the inductor in high-density PCBs and its interference to the surrounding environment. Furthermore, each group of coils and each group of two-stage coils is reliably isolated, improving the withstand voltage between the two-stage coils and the device performance. This results in a coupling coefficient greater than 0.8 between the primary coil groups and greater than 0.5 between the primary and two-stage coils. This further improves the circuit's operating environment and promotes hardware performance development in application scenarios such as servers and data centers. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the finished two-phase combined coupling inductor of this utility model.

[0016] Figure 2 yes Figure 1 The diagram shows the bottom view of the coupled inductor.

[0017] Figure 3 yes Figure 1 The exploded structure diagram of the coupled inductor shown is shown.

[0018] Figure 4 yes Figure 1 The diagram shows the assembly schematic of the coupled inductor.

[0019] Figure 5 This is a bottom view structural diagram of the finished three-phase combined coupling inductor of this utility model.

[0020] Figure 6 yes Figure 5 The exploded structure diagram of the coupled inductor shown is shown.

[0021] Figure 7 This is an exploded structural diagram of a magnetic core improvement of a two-phase combined coupled inductor according to this utility model.

[0022] Figure 8 yes Figure 7 The diagram shows a perspective view of the finished coupled inductor.

[0023] Figure 9 yes Figure 7 The diagram shows the bottom view of the finished coupled inductor.

[0024] Figure 10 This is an exploded structural diagram of another improved magnetic core of the two-phase combined coupled inductor of this utility model. Detailed Implementation

[0025] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.

[0026] This invention proposes a combined coupled inductor, aiming to improve the performance of inductor devices and optimize the space occupied by components in high-density PCBs. For example... Figures 1 to 4 As shown, the basic structure of a preferred embodiment of this combined coupled inductor is assembled from a prefabricated secondary coil 3, two or more primary coils 2, and a pair of magnetic cores 1 joined together to form a block. At least one magnetic core has a flat surface on one side and several parallel, spaced protrusions on the other side. The primary coils are continuously bent into a side-view "U" shape and are paired and connected to the protrusions to form two non-contact, side-by-side, mutually coupled primary inductors. The secondary coil 3 wraps around all the primary coils and is attached to the inner wall of the magnetic core to form a secondary inductor coupled to each primary inductor. The two magnetic cores are bonded together with flush edges. All the primary and secondary coils are formed into several staggered electrode pads on one side of the assembly.

[0027] As shown in the diagram, in this embodiment, the magnetic cores are formed as a pair with the same shape. One of the magnetic cores has a pair of sidewalls that clamp the protrusions, and a first protrusion 11 and a second protrusion 12 are formed between them at intervals. The tops of the two protrusions are recessed relative to the top surface of the magnetic core by a distance greater than the sum of the thicknesses of the two coils, and the bottoms of the two protrusions are flush with the bottom surface of the magnetic core. Correspondingly, the assembly also includes a first primary magnetic core 21 and a second primary magnetic core 22. After being aligned and fitted onto each of the protrusions, the two primary coils are encased by the secondary magnetic core 3. In the assembled state of the pair of magnetic cores, the sidewalls are assembled into a pair of sidewalls, and the inner protrusions are aligned and assembled into the inner core of the coil. As the basis for the inductor to connect to the PCB, all primary and secondary coils are formed on one side of the assembly (bottom side of the diagram) as follows: Figure 2 The figure shows several staggered electrode pads, all of which protrude from the surface of the assembly.

[0028] The aforementioned primary coil is an insert component formed by cutting and continuously bending a flat copper strip, and its surface is coated with an epoxy resin insulation layer to meet the insulation withstand voltage characteristics required by the TLVR circuit architecture. The width of the flat copper strip is smaller than the length of the protrusion after assembly. Figure 2 and Figure 3As shown in terms of the formed shape, the middle part of the flat copper strip lies flat on the top of the convex part, while both ends are bent downward from the convex part and skew-extend in different directions towards the adjacent magnetic cores until the bottom side of the convex part is bent relatively to wrap the convex part. Taking the first primary magnetic core 21 as an example, although the part bent downward on the outer side maintains a vertical surface shape, it skew-extends towards the magnetic core leaning to the right from top to bottom, while the part bent downward on the inner side skew-extends towards the magnetic core leaning to the left from top to bottom. Thus, a "fork" - shaped structure can be seen from the side view.

[0029] The above-mentioned secondary coil 3 is an embedded fitting formed by cutting and continuously bending a flat copper sheet insulated with insulating paint into a U - shape. The width of the flat copper sheet is the same as the length of the convex part after being assembled and formed, and the inner width of the secondary coil is greater than the sum of the outer widths of several primary coils that can be accommodated therein. Both ends of the secondary coil are bent outward and lean against the bottom side of the magnetic core.

[0030] As Figure 5 and Figure 6 shown, it is a preferred embodiment of the combined coupled inductor. The second magnetic core 10 has first convex part 11, second convex part 12 and third convex part 13 that are parallel and spaced apart, and the first primary coil 21, second primary coil 22 and third primary coil 23 are arranged in the same quantity and sleeved in one - to - one alignment. Then, a secondary coil 3 that can completely cover all the primary coils is sleeved outside. Then, a pair of second magnetic cores are assembled and integrally formed to obtain the finished product. The secondary coil forms first - group electrode pads 31, 32 on both sides in the length direction at the bottom of the assembly, and the three primary coils form second - group electrode pads 211, 212, third - group electrode pads 221, 222, and fourth - group electrode pads 231, 232 on both sides in the width direction at the bottom of the assembly, and the second to fourth - group electrode pads are arranged separately between the first - group electrode pads. In this embodiment, since the formed shape of the magnetic core is generally the same as that of the preferred embodiment, all the electrode pads protrude from the surface of the assembly.

[0031] As Figures 7 to 9 shown, it is another preferred embodiment of the combined coupled inductor. The third magnetic core 111 is also formed into a pair with the same outer shape. One of the magnetic cores 111 has a U - shaped convex edge (not marked) that sandwiches the convex part, and a left convex part 113 and a right convex part 114 are spaced apart inside the U - shaped convex edge. The tops of the two convex parts are indented from the top - side inner wall of the U - shaped convex edge by a distance greater than the sum of the thicknesses of two coils, and the bottoms of the convex parts are indented from the bottom - side end face of the U - shaped convex edge by a distance matching the thickness of the secondary coil. In the state where the pair of magnetic cores are assembled, the U - shaped convex edges are assembled into a top wall and a pair of side walls, and the inner convex parts are assembled into a coil inner core in alignment. On the basis of obtaining the assembly by assembling the third magnetic core in the same way, the secondary magnetic core 3 is no longer exposed at the top, and several groups of electrode pads flush with its own bottom surface are formed at the bottom of the assembly.

[0032] Please again Figure 10 The image shows another preferred embodiment of this combined coupled inductor. In this embodiment, the magnetic cores are formed as a pair with different shapes and flush edges. The first magnetic core 112' on the right is a square sheet, and the second magnetic core 112 on the left is a double-sided open cube enclosing a set of two equally spaced protrusions 115 and 116. The gap between the top of the protrusion and the inner wall of the top side of the second magnetic core on the left is greater than the sum of the thicknesses of the two coils. The bottom of the protrusion is recessed relative to the bottom surface of the second magnetic core on the left by a distance matching the thickness of the secondary coil. Thus, the first magnetic core on the right is close to the second magnetic core on the left and flush edges are joined together.

[0033] The magnetic cores in the above embodiments are prefabricated assemblies based on powder materials and customized molds, specifically using a cold-pressing process. The magnetic core is primarily made of iron-based soft magnetic powder, and includes one or more of the following magnetic powders: carbonyl CIP, Fe-Si-Cr, Fe-Si-Al, Fe-Si, amorphous, nanocrystalline, FeNi, MPP, FeNiMo-C, Si, Fe-Co-Ni, Fe-Al-B, MnZn, and NiZn. It may also contain nickel, manganese, magnesium, copper, zinc, boron, lithium, sodium, carbon, cobalt, niobium, barium, palladium, potassium, bismuth, graphene, amorphous, and nanocrystalline aluminum-line alloy. It is composed of one or more metallic elements, oxides, or carbonates, mixed with trace amounts (1.5%~4.5% by weight) of organic resin, epoxy resin, or aldehyde resin as a binder. After thorough mixing, it is injected into a custom mold conforming to the shape of the device and cold-pressed. The resulting assembly can be formed by distributing adhesive between the two magnetic cores and their protrusions and cold-pressing them into one piece, or by directly hot-pressing them together. Hot-pressing conditions: heating temperature 150℃~200℃, molding pressure between 5T / cm. 3 Hold pressure for 60s~120s.

[0034] In summary, the preferred embodiment of this utility model's combined coupled inductor, as detailed above, demonstrates the following technical advantages compared to existing technologies: By optimizing the prefabricated shape of the core and the two-stage coils to improve the assembly structure, it helps reduce the space occupied by the inductor in high-density PCBs and its interference to the surrounding environment. Furthermore, reliable isolation is achieved between each group of coils and between each group of two-stage coils, improving the withstand voltage and device performance between the two-stage coils. This results in a coupling coefficient greater than 0.8 between the primary coil groups and greater than 0.5 between the primary two-stage coils. This further improves the circuit's operating environment and promotes hardware performance development in application scenarios such as servers and data centers.

[0035] 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. A combined coupled inductor, characterized in that: The inductor is assembled from a prefabricated secondary coil, two or more primary coils, and a pair of magnetic cores joined together to form a block. At least one magnetic core has a flat surface on one side and several parallel and spaced protrusions on the other side. The primary coils are continuously bent into a side-view "U" shape and are paired and connected to the protrusions to form two non-contact, side-by-side, and mutually coupled primary inductors. The secondary coils wrap around all the primary coils and are attached to the inner wall of the magnetic cores to form secondary inductors coupled to each primary inductor. The two magnetic cores are bonded together with flush edges. All the primary and secondary coils are formed into several staggered electrode pads on one side of the assembly.

2. The combined coupled inductor according to claim 1, characterized in that: The magnetic cores are formed as a pair with the same shape. One of the magnetic cores has a pair of sidewalls that clamp the protrusions. The protrusions are arranged at equal intervals in pairs, and the top of the protrusion is recessed relative to the top surface of the magnetic core by a distance greater than the sum of the thicknesses of the two coils. The bottom of the protrusion is flush with the bottom surface of the magnetic core. When the pair of magnetic cores are assembled, the sidewalls are assembled into a pair of sidewalls, and the inner protrusions are aligned and assembled into the inner core of the coil.

3. The combined coupled inductor according to claim 1, characterized in that: The magnetic cores are formed as a pair with the same shape. One of the magnetic cores has a U-shaped convex edge that clamps the protrusion. The protrusions are arranged at equal intervals in pairs. The top of the protrusion is recessed relative to the inner wall of the top side of the U-shaped convex edge by a distance greater than the sum of the thicknesses of the two coils. The bottom of the protrusion is recessed relative to the bottom end face of the U-shaped convex edge by a distance matching the thickness of the secondary coil. When the pair of magnetic cores are assembled, the U-shaped convex edges are assembled into a top wall and a pair of side walls, and the inner protrusions are aligned and assembled into the inner core of the coil.

4. The combined coupled inductor according to claim 1, characterized in that: The magnetic cores are formed as a pair with different shapes and flush edges. The first magnetic core is a square sheet, and the second magnetic core is a double-sided open cube enclosing equally spaced protrusions. The gap between the top of the protrusion and the inner wall of the top side of the second magnetic core is greater than the sum of the thicknesses of the two coils. The bottom of the protrusion is recessed relative to the bottom surface of the second magnetic core by a distance matching the thickness of the secondary coil. The first magnetic core is attached to the second magnetic core and flush edges are joined together.

5. The combined coupled inductor according to claim 1, characterized in that: The primary coil is an embedded accessory formed by cutting and continuously bending a flat copper strip, and the surface of the primary coil is coated with an epoxy resin insulating layer; the width of the flat copper strip is less than the length of the protrusion after assembly, and both ends of the flat copper strip are bent downward from the top side of the protrusion and extend obliquely towards the adjacent magnetic core in opposite directions until the bottom side of the protrusion is bent relative to the protrusion and wraps around the protrusion.

6. The combined coupled inductor according to claim 1, characterized in that: The secondary coil is an inlay fitting made of flat copper sheet with insulating enamel coating, cut and continuously bent into a U-shape. The width of the flat copper sheet is consistent with the length of the protrusion after assembly. The inner width of the secondary coil is greater than the sum of the outer widths of several primary coils contained therein. The two ends of the secondary coil are bent outward and attached to the bottom side of the magnetic core.

7. The combined coupled inductor according to claim 1, characterized in that: The magnetic core has three parallel, spaced protrusions, and each protrusion is fitted with a primary coil. The secondary coil wraps around all the primary coils and is attached to the inner wall of the magnetic core.

8. The combined coupled inductor according to claim 1, characterized in that: The magnetic core is a cold-pressed molded body made of powder material based on a customized mold. The two magnetic cores in pairs and their protrusions are distributed and glued together and cold-pressed into one piece or directly assembled and hot-pressed into one piece.

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