A coil assembly and tlvr coupled inductor

Abstract

The utility model discloses a coil assembly and TLVR coupling inductor belong to electronic component technical field. Coil assembly includes primary coil and secondary coil, and primary coil includes first pin, and secondary coil includes second pin, and the end of first pin is equipped with first terminal PIN leg and the first insulating part of ring and is equipped with the first terminal PIN leg all around, and the end of second pin is equipped with second terminal PIN leg and the second insulating part of ring and is equipped with second terminal PIN leg all around, and first terminal PIN leg and second terminal PIN leg are all used for conducting connection, prevent the problem of electrical short circuit or voltage drop.

Description

Technical Field

[0001] This utility model relates to the field of electronic component technology, and in particular to a coil assembly and a TLVR coupled inductor. Background Technology

[0002] The core innovation of TLVR (Trans-Inductor Voltage Regulator) voltage regulators lies in replacing the discrete power inductor in traditional Buck circuits with a dual-winding coupled inductor. Specifically, the TLVR coupled inductor has a primary and a secondary coil. Both the primary and secondary coil pins are used for conductive connections. However, the spacing between these pins is small. Due to manufacturing defects or design flaws, unexpected conductive paths can form between adjacent pins, leading to electrical short circuits or a drop in withstand voltage. Furthermore, the magnetic core used to enclose the primary and secondary coils in the TLVR coupled inductor, when resistivity is low, can cause contact between the core and the pins due to manufacturing defects or design issues, resulting in an electrical short circuit. Utility Model Content

[0003] The purpose of this invention is to provide a coil assembly and a TLVR coupled inductor to prevent electrical short circuits or voltage drop.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] A coil assembly includes a primary coil and a secondary coil. The primary coil includes a first pin, and the secondary coil includes a second pin. The end of the first pin is provided with a first terminal pin and a first insulating portion surrounding the first terminal pin. The end of the second pin is provided with a second terminal pin and a second insulating portion surrounding the second terminal pin. Both the first terminal pin and the second terminal pin are used for conductive connection.

[0006] In some possible implementations, the thickness of the first insulating portion is greater than 10 μm, and the thickness of the second insulating portion is greater than 10 μm.

[0007] In some possible implementations, the minimum distance between the inner and outer edges of the first insulating portion is greater than or equal to 0.1 mm; the minimum distance between the inner and outer edges of the second insulating portion is greater than or equal to 0.1 mm.

[0008] In some possible implementations, the primary coil further includes a first body with both ends corresponding to the two first pins, and the edges of the first terminal pins are provided with a first extension to increase the cross-sectional area of ​​the first terminal pins; the secondary coil further includes a second body with both ends corresponding to the two second pins, and the edges of the second terminal pins are provided with a second extension to increase the cross-sectional area of ​​the second terminal pins.

[0009] In some possible implementations, the first body is connected to the first pin at both ends along the first direction, and the first terminal PIN is provided with the first extension at the edge along the second direction; the second body is connected to the second pin at both ends along the first direction, and the second terminal PIN is provided with the second extension at the edge along the second direction, and the first direction and the second direction are arranged at an angle.

[0010] In some possible implementations, the first terminal pin is flattened to form the first extension; the second terminal pin is flattened to form the second extension.

[0011] In some possible implementations, the width of the first extension is greater than 0.1 mm, and the width of the second extension is greater than 0.1 mm.

[0012] In some possible implementations, the first pin further includes a first bend at its end, with the first terminal PIN disposed at the first bend; the second pin further includes a second bend at its end, with the second terminal PIN disposed at the second bend.

[0013] In some possible implementations, the surface of the first pin is provided with an insulating layer, and the insulating layer at the end of the first pin is laser-stripped to form a window and a first insulating portion located around the window, and the first terminal PIN includes an electroplated layer disposed in the window; the surface of the second pin is provided with an insulating layer, and the insulating layer at the end of the second pin is laser-stripped to form a window and a second insulating portion located around the window, and the second terminal PIN includes an electroplated layer disposed in the window.

[0014] A TLVR coupled inductor includes a magnetic core and a coil assembly as described in any of the preceding claims, wherein a portion of the primary coil and a portion of the secondary coil are enclosed by the magnetic core, and a first terminal pin and a second terminal pin are exposed outside the magnetic core.

[0015] The beneficial effects of this utility model are:

[0016] This invention provides a coil assembly and a TLVR coupled inductor. By setting a first insulating portion around the first terminal pin and a second insulating portion around the second terminal pin, insulation spacing is achieved between the first terminal pin and the magnetic core, as well as between the second terminal pin and the magnetic core. This prevents direct contact between the first terminal pin and the magnetic core due to manufacturing defects, and thus prevents short circuits between the magnetic core and the first and second terminal pins, leading to poor withstand voltage and ultimately withstand voltage failure. Furthermore, by setting the first insulating portion around the first terminal pin and the second insulating portion around the second terminal pin, insulation isolation is achieved between the first and second terminal pins, preventing short circuits or voltage drop between them, thereby improving the reliability of the TLVR coupled inductor. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a TLVR coupled inductor provided in a specific embodiment of this utility model from one perspective;

[0018] Figure 2 This is a schematic diagram of the TLVR coupled inductor provided in a specific embodiment of this utility model from another perspective;

[0019] Figure 3 This is a schematic diagram of a coil assembly provided in a specific embodiment of this utility model.

[0020] In the picture:

[0021] 100, Magnetic core; 110, Side surface; 200, Coil assembly; 210, Primary coil; 211, First pin; 2111, First terminal pin; 2112, First bend; 2113, First extension; 2114, First insulation; 212, First body; 220, Secondary coil; 221, Second pin; 2211, Second terminal pin; 2212, Second bend; 2213, Second extension; 2214, Second insulation; 222, Second body. Detailed Implementation

[0022] To make the technical problems solved by this utility model, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of this utility model will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0023] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0024] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0025] This embodiment provides a coil assembly and a TLVR coupled inductor including the coil assembly. For example... Figures 1-3 As shown, the coil assembly 200 includes a primary coil 210 and a secondary coil 220. The primary coil 210 includes a first pin 211, and the secondary coil 220 includes a second pin 221. The end of the first pin 211 is provided with a first terminal PIN 2111 and a first insulating portion 2114 surrounding the first terminal PIN 2111. The end of the second pin 221 is provided with a second terminal PIN 2211 and a second insulating portion 2214 surrounding the second terminal PIN 2211. Both the first terminal PIN 2111 and the second terminal PIN 2211 are used for conductive connection.

[0026] The TLVR coupled inductor also includes a magnetic core 100, with a portion of the primary coil 210 and a portion of the secondary coil 220 encased within the magnetic core 100. The first terminal pin 2111 and the second terminal pin 2211 are exposed outside the magnetic core 100 for conductive connection. For example, when the TLVR coupled inductor is mounted on a circuit board or similar structure, the first terminal pin 2111 and the second terminal pin 2211 are used for conductive connection with the circuit board. When the circuit board is energized, the TLVR coupled inductor operates.

[0027] The magnetic material used to manufacture the magnetic core 100 (such as ferrite or metal magnetic powder composite material) has low resistivity in some metal magnetic powders (such as Fe and Co), which makes the magnetic core 100 conductive. By setting a first insulating portion 2114 around the first terminal PIN 2111 and a second insulating portion 2214 around the second terminal PIN 2211, an insulating gap is achieved between the first terminal PIN 2111 and the magnetic core 100, as well as between the second terminal PIN 2211 and the magnetic core 100. This prevents direct contact between the first terminal PIN 2111 and the magnetic core 100, and between the second terminal PIN 2211 and the magnetic core 100, due to process defects. Such direct contact would lead to a short circuit between the magnetic core 100 and the first terminal PIN 2111 and the second terminal PIN 2211, resulting in poor withstand voltage of the magnetic core 100 and ultimately, withstand voltage failure. Furthermore, by setting a first insulating portion 2114 around the first terminal PIN 2111 and a second insulating portion 2214 around the second terminal PIN 2211, insulation isolation is achieved between the first terminal PIN 2111 and the second terminal PIN 2211, preventing short circuits or voltage drops between them, thereby improving the reliability of the TLVR coupled inductor.

[0028] The thickness of the first insulating portion 2114 is greater than 10 μm. For example, the thickness of the first insulating portion 2114 can be 11 μm, 12 μm, or 13 μm, etc., and is not limited. The thickness of the second insulating portion 2214 is greater than 10 μm. For example, the thickness of the second insulating portion 2214 can be 11 μm, 12 μm, or 13 μm, etc. By setting a minimum thickness for the first insulating portion 2114 and the second insulating portion 2214, exposure due to excessively low thickness is prevented, thus ensuring insulation effectiveness.

[0029] The minimum distance between the inner and outer edges of the first insulating portion 2114 is greater than or equal to 0.1 mm. In some embodiments, the first insulating portion 2114 is a regular ring, such as a circular ring or a rectangular ring, with a fixed width, meaning the distance between the inner and outer edges is a fixed value, and the width is greater than or equal to 0.1 mm, such as 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, or 0.5 mm. In other embodiments, the first insulating portion 2114 is an irregular ring, meaning the distance between the inner and outer edges varies, with a minimum distance of 0.1 mm, such as 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, or 0.5 mm. Similarly, the minimum distance between the inner and outer edges of the second insulating portion 2214 is greater than or equal to 0.1 mm. In some embodiments, the second insulating portion 2214 is a regular ring shape, such as a circular ring or a rectangular ring, with a fixed width, meaning the distance between its inner and outer edges is a fixed value, and the width is greater than or equal to 0.1 mm, such as 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, or 0.5 mm. In other embodiments, the second insulating portion 2214 is an irregular ring shape, meaning the distance between its inner and outer edges varies, with a minimum distance of 0.1 mm, such as 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, or 0.5 mm. By setting the minimum distance between the inner and outer edges of the first insulating portion 2114 and the second insulating portion 2214, insulation reliability is ensured.

[0030] An insulating layer is provided on the surface of the first pin 211. Laser stripping is performed on the insulating layer at the end of the first pin 211 to form a window and a first insulating portion 2114 located around the window. The first terminal PIN 2111 includes an electroplated layer disposed on the window. An electroplated layer is formed on the window to create the first terminal PIN 2111. By setting the minimum values ​​of the inner and outer edges of the first insulating portion 2114, it is prevented that during the electroplating process, the electroplated layer extends to overlap with the magnetic core 100, causing direct contact between the first terminal PIN 2111 and the magnetic core 100, resulting in poor withstand voltage of the magnetic core 100 and ultimately, withstand voltage failure.

[0031] Similarly, the surface of the second pin 221 is provided with an insulating layer. Laser stripping is performed on the insulating layer at the end of the second pin 221 to form a window and a second insulating portion 2214 located around the window. The second terminal pin 2211 includes an electroplated layer disposed on the window. An electroplated layer is formed on the window to create the second terminal pin 2211. By setting the minimum values ​​of the inner and outer edges of the second insulating portion 2214, it is prevented that during the electroplating process, the electroplated layer extends to overlap with the magnetic core 100, causing direct contact between the second terminal pin 2211 and the magnetic core 100, resulting in poor withstand voltage of the magnetic core 100 and ultimately leading to withstand voltage failure.

[0032] The primary coil 210 includes two first pins 211 and a first body 212 connected to the two first pins 211 at both ends. The edge of the first terminal pin 2111 has a first extension 2113 to increase its cross-sectional area. The secondary coil 220 includes two second pins 221 and a second body 222 connected to the second pins 221 at both ends. The edge of the second terminal pin 2211 has a second extension 2213 to increase its cross-sectional area. By increasing the cross-sectional areas of the first and second terminal pins 2111 and 2211, the contact area for conductive connection is increased, thereby increasing the current density. Both the primary coil 210 and the secondary coil 220 are integral structures. The first terminal pin 2111 is flattened to form the first extension 2113; the second terminal pin 2211 is flattened to form the second extension 2213.

[0033] The first body 212 is connected to the first pin 211 at both ends along the first direction, and the first terminal PIN 2111 is provided with a first extension 2113 along the edge of the second direction. The first direction and the second direction are arranged at an angle. The second body 222 is connected to the second pin 221 at both ends along the first direction, and the second terminal PIN 2211 is provided with a second extension 2213 along the edge of the second direction. This restricts the position of the first extension 2113 and the second extension 2213, preventing the coil assembly 200 from being too large in the first direction, which would cause the TLVR coupled inductor to be too large in the first direction.

[0034] In some embodiments, the first extension 2113 is divided into two parts and disposed on both sides of the first terminal PIN 2111 along the second direction, and is symmetrically arranged. Similarly, the second extension 2213 is divided into two parts and disposed on both sides of the second terminal PIN 2211 along the second direction, and is symmetrically arranged. In other embodiments, the first extension 2113 is disposed on one side of the first terminal PIN 2111 along the second direction, and the second extension 2213 is disposed on one side of the second terminal PIN 2211 along the second direction. The first extension 2113 and the second extension 2213 are located on the same side of the first terminal PIN 2111 and the second terminal PIN 2211 along the second direction.

[0035] The width of the first extension 2113 is greater than 0.1 mm. When the first extension 2113 is divided into two parts located on both sides of the first terminal PIN 2111 along the second direction, the sum of the two parts, H1 + H2, is greater than 0.1 mm. For example, it is 0.2 mm, 0.3 mm, 0.4 mm, etc. The width of the second extension 2213 is greater than 0.1 mm. When the second extension 2213 is divided into two parts located on both sides of the second terminal PIN 2211 along the second direction, the sum of the two parts is greater than 0.1 mm. For example, it is 0.2 mm, 0.3 mm, 0.4 mm, etc.

[0036] The first pin 211 further includes a first bent portion 2112 disposed at its end, and a first terminal PIN 2111 disposed at the first bent portion 2112; the second pin 221 further includes a second bent portion 2212 disposed at its end, and a second terminal PIN 2211 disposed at the second bent portion 2212. By bending, the cross-sectional area of ​​the first bent portion 2112 is larger than the cross-sectional area of ​​the first pin 211, and the cross-sectional area of ​​the second bent portion 2212 is larger than the cross-sectional area of ​​the second pin 221. This increases the cross-sectional area of ​​the first terminal PIN 2111 on the first bent portion 2112 and the cross-sectional area of ​​the second terminal PIN 2211 on the second bent portion 2212, thereby increasing the contact area for conductive connection and increasing the flow density.

[0037] In some embodiments, in the primary coil 210, the first body 212 is connected to the two ends of the first pin 211 along the first direction, and the first pin 211 is provided with a first bend 2112 on the side opposite to each other. The first bend 2112 is flattened to form a first extension 2113 along the second direction. In the secondary coil 220, the second body 222 is connected to the two ends of the second pin 221 along the first direction, and the second pin 221 is provided with a second bend 2212 on the side facing each other. The second bend 2212 is flattened to form a second extension 2213 along the second direction.

[0038] The assembly steps of the TLVR coupled inductor include: forming an insulating layer on the surface of the primary coil 210 and the secondary coil 220, exemplarily, the insulating layer being a polyimide film layer or other polymer resin material layer. Optionally, the insulating layer is formed by an encapsulation process. The secondary coil 220 is embedded within the primary coil 210, with the first body 212 and the second body 222 parallel, and the first pin 211 and the second pin 221 parallel, with the two first pins 211 located on both sides of the two second pins 221 along a first direction. The magnetic core 100, the primary coil 210, and the secondary coil 220 are formed into an integral structure by a hot-pressing process. Windows are created on the first pin 211 and the second pin 221 by laser stripping, forming a first insulating portion 2114 and a second insulating portion 2214. An electroplated layer is deposited at the window of the first pin 211 to form a first terminal pin 2111, and an electroplated layer is deposited at the window of the second pin 221 to form a second terminal pin 2211. The first terminal pin 2111 and the second terminal pin 2211 are exposed on the side 110 of the magnetic core 100. The first terminal pin 2111, the second terminal pin 2211 and the side 110 are coplanar.

[0039] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A coil assembly, characterized in that, The device includes a primary coil (210) and a secondary coil (220). The primary coil (210) includes a first pin (211), and the secondary coil (220) includes a second pin (221). The end of the first pin (211) is provided with a first terminal pin (2111) and a first insulating portion (2114) surrounding the first terminal pin (2111). The end of the second pin (221) is provided with a second terminal pin (2211) and a second insulating portion (2214) surrounding the second terminal pin (2211). Both the first terminal pin (2111) and the second terminal pin (2211) are used for conductive connection.

2. The coil assembly according to claim 1, characterized in that, The thickness of the first insulating part (2114) is greater than 10 μm, and the thickness of the second insulating part (2214) is greater than 10 μm.

3. The coil assembly according to claim 1, characterized in that, The minimum distance between the inner and outer edges of the first insulating part (2114) is greater than or equal to 0.1 mm; the minimum distance between the inner and outer edges of the second insulating part (2214) is greater than or equal to 0.1 mm.

4. The coil assembly according to claim 1, characterized in that, The primary coil (210) further includes a first body (212) whose two ends are connected to the two first pins (211), and the edge of the first terminal pin (2111) is provided with a first extension (2113) to increase the cross-sectional area of ​​the first terminal pin (2111); the secondary coil (220) further includes a second body (222) whose two ends are connected to the two second pins (221), and the edge of the second terminal pin (2211) is provided with a second extension (2213) to increase the cross-sectional area of ​​the second terminal pin (2211).

5. The coil assembly according to claim 4, characterized in that, The first body (212) is connected to the first pin (211) at both ends along the first direction, and the first terminal PIN (2111) is provided with the first extension (2113) along the edge of the second direction; the second body (222) is connected to the second pin (221) at both ends along the first direction, and the second terminal PIN (2211) is provided with the second extension (2213) along the edge of the second direction, and the first direction and the second direction are arranged at an angle.

6. The coil assembly according to claim 4, characterized in that, The first terminal pin (2111) is flattened to form the first extension (2113); the second terminal pin (2211) is flattened to form the second extension (2213).

7. The coil assembly according to claim 4, characterized in that, The width of the first extension (2113) is greater than 0.1 mm, and the width of the second extension (2213) is greater than 0.1 mm.

8. The coil assembly according to claim 1, characterized in that, The first pin (211) further includes a first bent portion (2112) disposed at its end, and the first terminal PIN (2111) is disposed at the first bent portion (2112); the second pin (221) further includes a second bent portion (2212) disposed at its end, and the second terminal PIN (2211) is disposed at the second bent portion (2212).

9. The coil assembly according to any one of claims 1-8, characterized in that, The surface of the first pin (211) is provided with an insulating layer. Laser stripping is performed on the insulating layer at the end of the first pin (211) to form a window and a first insulating portion (2114) located around the window. The first terminal PIN (2111) includes an electroplated layer provided in the window. The surface of the second pin (221) is provided with an insulating layer. Laser stripping is performed on the insulating layer at the end of the second pin (221) to form a window and a second insulating portion (2214) located around the window. The second terminal PIN (2211) includes an electroplated layer provided in the window.

10. A TLVR coupled inductor, characterized in that, Includes a magnetic core (100) and a coil assembly as described in any one of claims 1-9, wherein a portion of the primary coil (210) and a portion of the secondary coil (220) are both enclosed by the magnetic core (100), and a first terminal pin (2111) and a second terminal pin (2211) are exposed on the magnetic core (100).

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