Integrated one-piece tlvr inductor
By using an integrated, one-piece molded TLVR inductor, the problems of large space occupation and numerous solder joints when increasing the inductance value of TLVR inductors are solved, thereby achieving circuit simplicity and improved reliability, while reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN GENGXING ELECTRONIC TECHNOLOGY CO LTD
- Filing Date
- 2025-04-28
- Publication Date
- 2026-06-16
AI Technical Summary
Increasing the inductance value of existing TLVR inductors results in a large PCB space requirement, increased costs, and impact on fast transient response. Furthermore, the increased number of solder joints leads to increased circuit complexity.
The integrated TLVR inductor is formed by molding the primary and secondary windings together with a mold, using reduced iron powder to reduce solder joints, and using flat enameled wire to improve reliability.
Significantly reduces the size and number of solder joints, improves circuit reliability, simplifies circuit design, and reduces manufacturing costs.
Smart Images
Figure CN224366646U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of inductor technology, and in particular to an integrated TLVR inductor that is integrated and arranged on a circuit board, thereby reducing the number of SMD (Surface Mount Device) solder points and improving circuit reliability. Background Technology
[0002] An inductor is a passive electronic component, also known as an inductor coil, consisting of a coil wound around a core. The primary purpose of an inductor is to store and control electrical energy in the form of magnetic energy by generating a magnetic field around the coil to resist changes in the current flowing through it. This characteristic makes inductors play a crucial role in various electrical and electronic applications. However, when the inductor's load changes drastically, the output voltage exhibits a reactive state—the process by which the output voltage rises or falls and then returns to its set value—known as transient response.
[0003] In view of the problems of the aforementioned inductors, the Trans-Inductor Voltage Regulator (TLVR) was developed. It is a novel structure of coupled inductor. The purpose of this circuit is to correct problems such as voltage sag and reduce ripple rate. TLVR inductors have greater current tolerance and a more robust body.
[0004] TLVR inductors basically consist of a primary winding and a secondary winding. When the ratio of the number of primary windings to secondary windings is 1:1, although the voltage of the primary winding and the secondary winding does not change, a fast transient response can be achieved to correct voltage sags and reduce ripple rate, thereby improving the reliability of the circuit.
[0005] Increasing the inductance value helps to achieve a faster transient response. However, increasing the inductance value of a TLVR inductor inevitably requires increasing the number of phases. More phases mean more PCB space is required. On the other hand, a smaller inductance value will affect the fast transient response. Therefore, the current technology increases the number of phases of the TLVR inductor while increasing the inductance value to the saturation value to avoid reducing the conversion efficiency too much. However, it is also necessary to avoid using too many TLVR inductors, which would occupy a larger PCB area and increase costs. Therefore, reducing the size of the TLVR inductor while increasing the inductance value has become a technical challenge.
[0006] In view of the aforementioned problems, the designer of this project, based on the known shortcomings of inductors, began research and development and improvement. Through repeated experiments and modifications, the designer was finally able to complete an inductor device with a small appearance size and reduced solder joints of the inductor on the PCB. Utility Model Content
[0007] The main purpose of this invention is to provide an integrated, one-piece molded TLVR inductor, wherein the primary winding and the secondary winding are integrally molded by pressure through a mold, which not only significantly reduces the appearance size and welding points, improving practicality and durability, but also greatly reduces manufacturing costs.
[0008] Another objective of this invention is to provide an integrated, one-piece molded TLVR inductor, wherein multiple primary windings are arranged within a single frame to replace the complexity of circuit design caused by multiple conventional TLVR inductors, making the overall circuit design cleaner and simpler.
[0009] This utility model provides an integrated, one-piece molded TLVR inductor, comprising: at least two primary windings, a primary and a secondary winding, and a frame.
[0010] The primary windings are arranged in parallel sequence; the secondary windings surround the outside of each primary winding and are arranged in parallel with each primary winding on the same plane; the frame covers each primary winding and the secondary windings, and after high voltage, the frame, each primary winding and the secondary winding are formed as a whole.
[0011] Each primary winding has two first welding feet, and each first welding foot is located at the bottom of both ends of the primary winding.
[0012] The secondary winding has two second welding feet, each located at the bottom of both ends of the secondary winding.
[0013] The frame is made by covering the primary and secondary windings with reduced iron powder.
[0014] Each primary winding has a winding area, which is arranged around the outside of each primary winding.
[0015] Each primary winding is made by wrapping flat enameled wire around the winding area.
[0016] The relative permeability of each primary winding and secondary winding is between 50 and 150.
[0017] In summary, the main purpose of this utility model is to make the primary and secondary windings from reduced iron powder, and after molding under high pressure in a mold, the appearance size can be significantly reduced, the number of welding points can be reduced, and the reliability of the primary and secondary windings will be higher. Attached Figure Description
[0018] Figure 1 This is a three-dimensional schematic diagram of the primary winding of this utility model;
[0019] Figure 2 This is a three-dimensional schematic diagram of the combination of the primary winding and the secondary winding of this utility model;
[0020] Figure 3 This is a three-dimensional schematic diagram of the integrated, one-piece molded TLVR inductor of this utility model;
[0021] Figure 4 This is a schematic diagram showing the combination of the primary and secondary windings of this integrated molded TLVR inductor with a 3:1 configuration.
[0022] Figure 5 This is a schematic diagram of the structure of the primary winding of the integrated molded TLVR inductor, which is wound with flat enameled wire.
[0023] Explanation of reference numerals in the attached diagram: 100 - primary winding; 110 - first welding foot; 120 - winding area; 200 - secondary winding; 210 - second welding foot; 300 - frame. Detailed Implementation
[0024] The specific embodiments of the present invention will now be described in conjunction with the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art and can be implemented accordingly.
[0025] Please see Figure 1 Figures 3 to 3 show a three-dimensional schematic diagram of a combination of primary and secondary windings and a three-dimensional schematic diagram of an integrated, one-piece molded TLVR inductor according to the present invention. As shown in the figure, the present invention provides an integrated, one-piece molded TLVR inductor, including: at least two primary windings 100, primary and secondary windings 200, and a frame 300.
[0026] like Figure 1 As shown, each primary winding 100 is arranged in parallel with the side as a reference and at the same interval. Each primary winding 100 has two first welding feet 110, and each first welding foot 110 is located at the bottom of both ends of the primary winding 100.
[0027] like Figure 2 As shown, the secondary winding 200 surrounds the outer side of each primary winding 100. The secondary winding 200 and each primary winding 100 are arranged in parallel on the same plane. The secondary winding 200 has two second welding feet 210, and each second welding foot 210 is located at the bottom of both ends of the secondary winding 200.
[0028] like Figure 3 As shown, the frame 300 covers each primary winding 100 and secondary winding 200. After high voltage, the frame 300, each primary winding 100 and secondary winding 200 are integrally formed. The first welding foot 110 of each primary winding 100 is located at the bottom of the integrally formed frame 300.
[0029] In practice, this invention first arranges the primary winding 100 and the secondary winding 200, then uses a mold to die-cast the arranged primary winding 100 and secondary winding 200 with reduced iron powder. Finally, after high-pressure die-casting with reduced iron powder, the resulting frame 300 covers the primary winding 100 and secondary winding 200, making each primary winding 100, secondary winding 200 and frame 300 integrally formed. This integral forming can significantly reduce the size of the TLVR inductor. The number of solder points between the primary winding 100 and secondary winding 200 and the PCB will be reduced. The fewer the number of solder points, the stronger the durability of the primary winding 100 and secondary winding 200 and the higher the number of uses.
[0030] Thus, when the primary winding 100 and the secondary winding 200 induce each other to function as inductors, one set of primary windings 100 is a single-phase inductor, and the two sets of primary windings 100 are two-phase inductors. This embodiment uses a two-phase inductor as an example. The two primary windings 100 are placed in parallel, and the inductance value of the secondary winding 200 is equal to the sum of the inductance values of the two primary windings 100. A larger inductance value results in less current stress on the capacitor and is also beneficial for reducing output voltage ripple. However, a larger inductance value results in a larger size, which means higher cost. But this utility model adopts an integrated molding design, which not only significantly reduces the size of the appearance but also significantly reduces manufacturing costs.
[0031] Please see Figure 4 The illustration shows another embodiment of the integrated molded TLVR inductor of this utility model. Currently, molded TLVR inductors all use a single TLVR inductor to complete the design of a single-phase circuit. A single-phase circuit refers to a circuit that uses a set of primary windings 100 and a set of secondary windings 200 for power supply. If there are more than one phase, such as a three-phase circuit, three single TLVR inductors are required to complete the overall circuit design. The single TLVR inductor design occupies a large area of PCB and has many solder points. This embodiment adopts a 3:1 configuration of primary windings 100 and secondary windings 200, placing the three primary windings 100 in parallel. The first soldering pin 110 and the second soldering pin 210 are both concentrated in the same TLVR inductor. Therefore, the PCB area occupied by the TLVR inductor can be reduced, and the number of SMD solder points can be reduced. Of course, if needed and the size permits, more primary windings 100 can be added.
[0032] In addition, saturation current refers to the critical point where the magnetic field no longer increases proportionally with the increase of current. That is, the primary winding 100 and the secondary winding 200 have become "saturated". In order to prevent the saturation value of the inductor from dropping too much, the reduced iron powder used in the frame 300 has a relative permeability of 50 to 150.
[0033] Please see Figure 5The figure shows a schematic diagram of the winding of the primary winding 100 of an integrated TLVR inductor of this utility model. As shown in the figure, the primary winding 100 of this utility model is wound with flat enameled wire. The flat enameled wire is convenient to wind with its flat surface around the primary winding. The flat enameled wire is wrapped around the winding area 120 in the figure. The outer surface of the enameled wire is wrapped with an insulating layer, which can not only prevent leakage between the primary winding 100 and the secondary winding 200, but also prevent short circuits caused by contact between the internal copper wires.
[0034] The embodiments listed above are only some embodiments of the present utility model, but are not intended to limit the scope of the present utility model patent. For those skilled in the art, any modifications and improvements derived therefrom without departing from the technical features of the present utility model are all within the protection scope of the present utility model.
Claims
1. An integrated, molded TLVR inductor, characterized in that, include: At least two primary windings are arranged in parallel and evenly distributed on the same plane; A secondary winding surrounds the outside of each of the primary windings arranged in parallel, and the secondary winding and each of the primary windings are arranged in parallel on the same plane; A frame is formed to cover each of the primary windings and the secondary windings. After being subjected to high voltage, the frame, each of the primary windings and the secondary windings are integrally formed.
2. The integrated, one-piece molded TLVR inductor as described in claim 1, characterized in that, Each primary winding has two first welding feet, each of which is located at the bottom of both ends of the primary winding.
3. The integrated, one-piece molded TLVR inductor as described in claim 1, characterized in that, The secondary winding has two second welding feet, each of which is located at the bottom of both ends of the secondary winding.
4. The integrated, one-piece molded TLVR inductor as described in claim 1, characterized in that, The frame is made of reduced iron powder.
5. The integrated, one-piece molded TLVR inductor as described in claim 4, characterized in that, The relative permeability of the reduced iron powder is between 50 and 150.
6. The integrated, one-piece molded TLVR inductor as described in claim 1, characterized in that, Each primary winding has a winding region that surrounds the outside of each primary winding.
7. The integrated, one-piece molded TLVR inductor as described in claim 6, characterized in that, Each primary winding is made by wrapping flat enameled wire around the winding area.