A combined high-current inductor

Abstract

The utility model discloses a combined type large current inductance, including first magnetic core and second magnetic core, both are ED type iron silicon alloy magnetic core, both laminated settings and between the opposite two surfaces fill with the glass pearl of uniform distribution, the glass pearl is formed glass pearl gasket through epoxy resin bonding package, copper sheet primary winding and flat wire secondary winding, install in first magnetic core and second magnetic core, constitute inductance winding structure together, wherein, each component is assembled bonding through epoxy resin and forms an organic whole, the first magnetic core with the second magnetic core passes through the thickness adjustment inductance structure of glass pearl gasket and constitutes a closed magnetic field, the utility model discloses through glass pearl gasket adjustment magnetic field gap, has improved the magnetic flux coupling effect, adopts the combination design of copper sheet primary winding and flat wire secondary winding, has reduced winding resistance, when using together with multiphase step-down converter, can realize quick load transient response under the condition of minimum output capacitance.

Description

Technical Field

[0001] This utility model relates to the field of electronic components technology, specifically a combined high-current inductor. Background Technology

[0002] Voltage regulators and power management units play a crucial role in modern electronic devices and power systems, especially in high-performance computing devices such as server motherboards, data networks, and large data center storage systems. As these devices increasingly demand faster processing speeds and higher efficiency, traditional power supply designs face numerous challenges.

[0003] Because the transient response in traditional circuits relies on the capacitor bank at the circuit output, and the output filter inductor prevents the rapid current rise from the regulator, the required current cannot be provided in time when the load changes rapidly, causing instantaneous fluctuations in the output voltage. Furthermore, the polymer capacitors used in these circuits are typically at risk of lifespan degradation during use; over time, their capacitance and performance may significantly decrease, affecting the stability and reliability of the circuit.

[0004] To improve the transient response of a system, traditional designs typically increase the capacitance of the output capacitor. However, this approach not only increases the physical size and cost of the system but may also lead to a reduction in the power density of the power supply. The charging and discharging process of a larger capacitor also introduces additional power consumption, thereby reducing the overall efficiency of the system.

[0005] Therefore, how to achieve fast load transient response while minimizing output capacitance has become an urgent problem to be solved. Utility Model Content

[0006] The purpose of this invention is to provide a combined high-current inductor with fast multiphase voltage regulation. Through innovative core structure and winding design, it achieves fast load transient response while minimizing output capacitance, solving the lifespan degradation problem caused by reliance on capacitor banks in traditional circuits and the problem of output filter inductors hindering rapid current rise.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A combined high-current inductor, comprising:

[0009] The first magnetic core and the second magnetic core are both ED type iron-silicon alloy magnetic cores. They are stacked and filled with uniformly distributed glass beads between their two opposing surfaces. The glass beads are bonded and encapsulated with epoxy resin to form glass bead spacers.

[0010] A copper sheet primary winding is installed inside the first magnetic core and the second magnetic core;

[0011] A flat wire secondary winding is installed inside the first magnetic core and the second magnetic core, and together with the copper sheet primary winding, it forms an inductance winding structure;

[0012] Among them, each component is assembled and bonded into an integral body through epoxy resin. The first magnetic core and the second magnetic core adjust the inductance structure through the thickness of the glass bead gasket and form a closed magnetic field.

[0013] Preferably, first installation grooves are provided on both sides inside the first magnetic core, and second installation grooves are provided on both sides inside the second magnetic core. The second installation grooves are arranged opposite to the first installation grooves; the copper sheet primary winding is stacked on the outer surface of the flat wire secondary winding and then is clamped and installed between the first installation groove and the second installation groove.

[0014] Preferably, there are two first installation grooves, which are respectively located on the left and right sides inside the first magnetic core; there are two second installation grooves, which are respectively located on the left and right sides inside the second magnetic core and correspond to the first installation grooves.

[0015] Preferably, the diameter of the glass bead is 0.1 - 0.5 mm.

[0016] Preferably, the copper sheet primary winding includes a first bending section and first straight sections extending outward horizontally from both sides of the first bending section. The copper sheet primary winding as a whole has a "U" - shaped structure.

[0017] Preferably, the flat wire secondary winding includes a second bending section and second straight sections extending inward horizontally from both sides of the second bending section.

[0018] Preferably, the thickness of the copper sheet primary winding is greater than the thickness of the flat wire secondary winding.

[0019] Preferably, the thickness of the copper sheet primary winding is 0.8 - 1.5 mm, and the thickness of the flat wire secondary winding is 0.5 - 1.2 mm.

[0020] Preferably, the first magnetic core and the second magnetic core change the magnetic field gap by adjusting the thickness of the glass bead gasket, so as to adjust the inductance value to meet the requirements of different voltage regulating circuits.

[0021] Preferably, the flat wire secondary windings of multiple said combined high - current inductors can be connected in series and used in a multi - phase buck converter circuit.

[0022] Compared with the prior art, the beneficial effects of the present utility model are as follows:

[0023] 1) This invention employs a first magnetic core and a second magnetic core, and adjusts the inductor structure using glass bead spacers formed by uniformly distributed glass beads in between, creating a closed magnetic field. This improves the magnetic field utilization efficiency and magnetic flux coupling effect of the inductor. The thickness of the glass bead spacers allows for precise control of the gap between the magnetic cores, thereby precisely adjusting the inductance value to suit the needs of different voltage regulation circuits. This design significantly enhances the inductor's performance and power handling capability, enabling it to operate stably under high current conditions.

[0024] 2) This utility model employs a primary winding made of copper sheets and a secondary winding made of flat wires to form a high-efficiency transformer structure. This combined design allows the inductor to handle large currents while maintaining a small size, and to achieve efficient energy transfer and voltage conversion. The "U"-shaped design of the copper sheet primary winding and the special structure of the flat wire secondary winding not only reduce the DC resistance of the winding and reduce copper losses, but also optimize the magnetic flux path and improve the overall efficiency.

[0025] 3) When used in conjunction with a multiphase buck converter, the combined high-current inductor of this invention achieves a very fast load transient response with minimal output capacitance. This is because the inductor enables rapid energy transfer between different phases, reducing reliance on large-capacity output capacitors. This effectively solves the lifespan degradation problem caused by capacitor banks in traditional circuits, as well as the problem of output filter inductors hindering rapid current rise. Its transient response time can be significantly reduced from the traditional 40ms to 2-5ms, greatly improving the dynamic performance of the system.

[0026] 4) By reducing reliance on output capacitors, the inductor structure of this invention simplifies circuit design, reduces system cost and size, and increases power density. This is particularly important for space-constrained server motherboards, data networks, and large data center storage systems. Simultaneously, it reduces the use of short-life polymer capacitors, improving the long-term reliability and stability of the system. Attached Figure Description

[0027] Figure 1 This is one of the three-dimensional structural schematic diagrams of the inductor of this utility model;

[0028] Figure 2 This is the second three-dimensional structural schematic diagram of the inductor of this utility model;

[0029] Figure 3 This is one of the exploded structural diagrams of the inductor of this utility model;

[0030] Figure 4 This is the second exploded structural diagram of the inductor of this utility model.

[0031] In the diagram: 1. First magnetic core; 2. Second magnetic core; 3. Copper sheet primary winding; 4. Flat wire secondary winding; 5. Glass bead spacer. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] like Figures 1-4 As shown, the present invention provides a combined high-current inductor with fast multiphase voltage regulation, comprising a first magnetic core 1 and a second magnetic core 2, a copper sheet primary winding 3, a flat wire secondary winding 4, and a glass bead pad 5.

[0034] Both the first magnetic core 1 and the second magnetic core 2 are made of ED-type iron-silicon alloy material. This material has high saturation magnetic flux, low loss, and excellent temperature stability, making it particularly suitable for high-frequency, high-current inductor applications. The two magnetic cores are stacked, and uniformly distributed glass beads are filled between their opposing surfaces. These glass beads are encapsulated with epoxy resin to form glass bead spacers 5. The first magnetic core 1 has first mounting grooves on both sides inside, and the second magnetic core 2 has second mounting grooves on both sides inside. The second mounting grooves are opposite to the first mounting grooves and are used to mount the primary winding and the secondary winding.

[0035] Glass beads are evenly filled and distributed between the two opposing surfaces of the first magnetic core 1 and the second magnetic core 2, and are fixed by epoxy resin to form glass bead spacers 5. This design allows the two magnetic cores to maintain a stable spacing and alignment when stacked, not only fixing the position of the magnetic cores, but also providing the necessary mechanical support through the elasticity and hardness of the glass beads, preventing the magnetic cores from shifting or vibrating during high-current operation.

[0036] The diameter of the glass beads, ranging from 0.1 to 0.5 mm, directly affects the spacing between the two magnetic cores, thereby adjusting the magnetic flux path and coupling efficiency of the overall inductor structure. By selecting glass beads of different diameters, the distance between the magnetic cores can be precisely controlled, thus optimizing the magnetic flux coupling effect and improving the inductor's performance. Specifically, larger diameter glass beads increase the core spacing and reduce the magnetic flux density, suitable for applications requiring a lower coupling coefficient; while smaller diameter glass beads reduce the core spacing and increase the magnetic flux density, suitable for applications requiring a high coupling coefficient and efficient energy transfer. Therefore, the inductance value of the product can be adjusted by changing the diameter of the glass beads to meet the needs of different voltage regulation circuits. In practical applications, glass beads of appropriate size can be selected according to specific circuit requirements and bonded together with epoxy resin to form glass bead spacers 5 of different thicknesses.

[0037] The primary winding 3 is made of copper sheets with a thickness of 0.8~1.5mm. It includes a first bent section and a first straight section extending outward horizontally from both sides of the first bent section, forming an overall "U"-shaped structure. This design not only reduces the DC resistance of the winding and reduces copper losses, but also facilitates assembly and fixing. The high conductivity and large cross-sectional area of ​​the copper sheet enable it to carry large currents, making it suitable for use as a primary winding to handle high-power electrical energy conversion.

[0038] The flat wire secondary winding 4 is made of flat copper wire with a thickness of 0.5~1.2mm, including a second bent section and a second straight section extending inward horizontally from both sides of the second bent section. This design increases the surface area of ​​the coil, which is beneficial for heat dissipation, while maintaining good mechanical strength and electrical performance. The special shape of the flat wire gives it lower skin effect and proximity effect at high frequencies, improving energy transfer efficiency.

[0039] The copper sheet primary winding 3 is stacked on the outer surface of the flat wire secondary winding 4, and then snapped into place between the first and second mounting slots to form the inductor winding structure. The thickness of the primary winding is greater than that of the secondary winding. This differentiated design allows the primary winding to withstand a larger current, while the secondary winding is more flexible and easier to wire and connect in complex circuit layouts.

[0040] Two first mounting slots are provided, located on the left and right sides inside the first magnetic core 1, respectively; two second mounting slots are also provided, located on the left and right sides inside the second magnetic core 2, respectively, corresponding to the first mounting slots. This symmetrical slot design not only facilitates the installation of the windings but also ensures the uniformity and symmetry of the magnetic field distribution, which helps to improve the performance and stability of the inductor.

[0041] The components are assembled and bonded together using epoxy resin. Epoxy resin not only possesses excellent adhesive properties, firmly binding the magnetic core, windings, and glass bead spacers 5 together, but also provides good insulation properties, preventing electrical short circuits between the windings and the magnetic core. Furthermore, after curing, epoxy resin exhibits excellent mechanical strength and heat resistance, maintaining stability in harsh working environments and extending the inductor's lifespan.

[0042] In practical applications, the secondary windings of multiple combined high-current inductors with fast multiphase voltage regulation according to this invention can be connected in series for use in multiphase buck converter circuits. This application method can achieve higher power handling capacity and better heat distribution, making it suitable for applications with stringent power quality requirements, such as high-end server motherboards, data network equipment, and large data center storage systems.

[0043] The working principle of this novel combined high-current inductor with rapid multiphase voltage regulation is as follows: When current flows through the primary winding, magnetic flux is generated inside the magnetic core. Since the first magnetic core 1 and the second magnetic core 2 form a closed magnetic circuit, these magnetic fluxes are efficiently coupled to the secondary winding, realizing energy transfer. The magnetic core gap adjusted by the glass bead spacer 5 gives the magnetic circuit a certain magnetic reluctance, which helps to control the magnetic flux density and magnetic saturation phenomenon, improving the stability of the inductor under high current conditions.

[0044] In multiphase buck converter applications, multiple such inductor units work together, with each unit handling the current of one phase. When the load changes suddenly, such as from a light load to a heavy load, the output capacitor in a conventional circuit provides instantaneous current. However, due to the limited capacitance, the voltage drops rapidly, affecting system stability. The inductor structure of this invention enables rapid energy transfer between different phases. When one phase requires more current, other phases can quickly provide support through magnetic coupling, reducing reliance on large-capacity output capacitors and thus achieving a faster load transient response.

[0045] Compared to existing technologies, this invention employs an ED-type iron-silicon alloy magnetic core and uses intermediate glass bead spacers 5 to adjust the inductor structure, forming a closed magnetic field. This improves the inductor's magnetic field utilization efficiency and flux coupling effect, thereby enhancing its performance and power handling capacity. The copper sheet primary winding 3 and flat wire secondary winding 4 enable efficient energy transfer and voltage conversion. Furthermore, the secondary windings can be connected in series according to actual needs, improving the inductor's flexibility and adaptability.

[0046] By bonding the magnetic core and windings together with epoxy resin, the mechanical strength and reliability of the inductor are improved, while ensuring good insulation performance and preventing electrical short circuits between the windings and the magnetic core. This fast multiphase voltage-regulated combined high-current inductor, used in conjunction with a multiphase buck converter, achieves very fast load transient response with minimal output capacitance, reducing the transient response time from 40ms for traditional inductors to 2-5ms. This is because the coupled inductor enables rapid energy transfer between different phases, reducing reliance on large-capacity output capacitors and thus improving the system's dynamic performance.

[0047] By eliminating some of the output capacitors in traditional circuits, the inductor structure of this invention simplifies circuit design, reduces system cost and size, and increases power density, which is particularly important for space-constrained server motherboards and data center equipment. Furthermore, the multi-phase voltage-regulated combined high-current inductor of this invention exhibits excellent fast load transient response capability, effectively suppressing output voltage fluctuations and ensuring stable power output to meet the stringent requirements of high-performance electronic systems.

[0048] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0049] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A combined high-current inductor, characterized in that, Comprising: A first magnetic core and a second magnetic core, both of which are ED type iron-silicon alloy magnetic cores. The two are stacked and filled with uniformly distributed glass beads between two opposite surfaces. The glass beads are adhesively encapsulated by epoxy resin to form a glass bead gasket; A copper sheet primary winding, installed inside the first magnetic core and the second magnetic core; A flat wire secondary winding, installed inside the first magnetic core and the second magnetic core, and jointly constituting an inductor winding structure with the copper sheet primary winding; Wherein, each component is assembled and adhesively bonded by epoxy resin to form an integral body. The first magnetic core and the second magnetic core adjust the inductance structure through the thickness of the glass bead gasket and form a closed magnetic field.

2. The combined high-current inductor according to claim 1, characterized in that: On both sides inside the first magnetic core, there are first installation grooves. On both sides inside the second magnetic core, there are second installation grooves. The second installation grooves are arranged opposite to the first installation grooves. The copper sheet primary winding is stacked on the outer surface of the flat wire secondary winding and then clamped and installed between the first installation groove and the second installation groove.

3. The combined high-current inductor according to claim 2, characterized in that: There are two first installation grooves, located on the left and right sides inside the first magnetic core respectively. There are two second installation grooves, located on the left and right sides inside the second magnetic core respectively, and corresponding to the first installation grooves.

4. The combined high-current inductor according to claim 1, characterized in that: The diameter of the glass beads is 0.1~0.5mm.

5. The combined high-current inductor according to claim 1, characterized in that: The copper sheet primary winding includes a first bending section and first straight sections extending horizontally outward from both sides of the first bending section. The copper sheet primary winding as a whole has a "U" shaped structure.

6. The combined high-current inductor according to claim 1, characterized in that: The flat wire secondary winding includes a second bending section and second straight sections extending horizontally inward from both sides of the second bending section.

7. The combined high-current inductor according to claim 1, characterized in that: The thickness of the copper sheet primary winding is greater than the thickness of the flat wire secondary winding.

8. The combined high-current inductor according to claim 7, characterized in that: The thickness of the copper sheet primary winding is 0.8~1.5mm, and the thickness of the flat wire secondary winding is 0.5~1.2mm.

9. The combined high-current inductor according to claim 1, characterized in that: The first magnetic core and the second magnetic core change the magnetic field gap by adjusting the thickness of the glass bead gasket, thereby adjusting the inductance value to meet the requirements of different voltage regulating circuits.

10. The combined high-current inductor according to claim 1, characterized in that: The flat wire secondary windings of multiple said combined high-current inductors can be connected in series and used in a multi-phase buck converter circuit.

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