A multiphase push-type inductor

Abstract

The utility model discloses a kind of multi-phase row type inductors, by prefabricated array coil and a group of magnetic core assembly molding, wherein magnetic core main body is shaped as oblong block, and the side wall in three directions of magnetic core is flat, the remaining one long side wall is provided with two-to-one group array slot and penetrates top and bottom two sides, the slot aperture of the protruding post bottom formed between each group of slots is inwardly retracted by one slot, any group of coil has three folded sections of protruding post wrapped from bottom to top and electrode pad folded in opposite direction at both ends, coil is positioned in slot and a group of magnetic core is edge-bonded with protruding post opposite direction, wrap coil into an integral whole. The inductor effectively saves the space occupied by inductive device in PCB circuit, can meet the design requirement of smaller terminal product volume, and reduces the interference influence to periphery, further perfects the operation environment of circuit.

Description

Technical Field

[0001] This utility model relates to an inductor, and more particularly to a multiphase inductor, 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] Currently, in PCB circuit design, due to the specific types and quantities of inductors required, and the inevitable customer demand for miniaturized products, there is an increasing demand for such devices to occupy less space. Summary of the Invention

[0004] The purpose of this invention is to propose a multiphase array inductor, which aims to optimize the space occupancy of inductor devices under reuse conditions.

[0005] The technical solution of this utility model to achieve the above-mentioned objective is: a multi-phase array inductor, which is assembled from a pre-formed array of coils and a set of magnetic cores. The magnetic core body is formed into a rectangular block, and the sidewalls of the magnetic core in three directions are flat. The remaining long strip sidewall has array slots in pairs that extend through the top and bottom. The bottom of the protrusion formed between each set of slots of the magnetic core is recessed by the opening diameter of one slot. Any set of coils with the same shape has a three-fold section that wraps around the protrusion from bottom to top and electrode pads that are folded in opposite directions at both ends. The coil is positioned in the slot and a set of magnetic cores are glued and wrapped around the coil in the opposite direction of the protrusion.

[0006] Furthermore, the width of the coil in the three-fold section is half the width of the assembled magnetic core, and the electrode pads extend and widen to be flush with the sidewalls of the assembled magnetic core at both ends.

[0007] Furthermore, the flattened thickness of the coil is smaller than the slot opening diameter, and the coil is attached to the top surface of the magnetic core only by the electrode pads. The three folds of the coil are assembled with the slot and the bottom of the protrusion with clearance fit.

[0008] Furthermore, the magnetic core is a cold-pressed body made of powder material based on a customized mold.

[0009] Furthermore, the spacing between the two slots in each group is the same as or close to the spacing between the groups of slots, and an insulation gap is left between the electrode pads formed by the folding of adjacent coils.

[0010] Compared with the prior art, the advantages of applying this inductor are reflected in the following aspects: by optimizing the coil structure and multiple reusing multiple coils, and designing an assembly structure with multiple slots and multiple coil integration, it helps to reduce the space occupied by the inductor in high-density PCB components and the interference to the surrounding environment, and promotes the performance improvement of switch-mode power supplies in application scenarios such as servers / data centers. Attached Figure Description

[0011] Figure 1 This is a close-up structural diagram of the magnetic core in the inductor of this utility model from one perspective.

[0012] Figure 2 This is a close-up structural diagram of the magnetic core in the inductor of this utility model from another perspective.

[0013] Figure 3 This is a close-up structural diagram of the coil in the inductor of this utility model.

[0014] Figure 4 This is an assembly diagram of the multiphase inductor of this utility model. Detailed Implementation

[0015] 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.

[0016] This invention proposes a multiphase array inductor, aiming to improve the performance of inductor devices and optimize the space occupied by components in high-density PCBs. Figures 1 to 4 As shown, the basic structure of this inductor is assembled from a pre-formed array of coils 2 and a set of magnetic cores 1. An overview of the functional components follows... Figure 1 and Figure 2 One of the magnetic cores 1 shown is shaped as a rectangular block, with flat sidewalls (1a, 1b, 1c) on three sides. The remaining elongated sidewall 1d has a series of slots 11 arranged in pairs, extending through the top and bottom surfaces. The bottom of the protrusion 12 formed between each set of slots is recessed by the diameter of one slot opening, thus horizontally connecting the two separate slots into one unit. In the preferred embodiment shown, four sets of slots are actually provided. Any set of coils 2 with the same shape is formed by cutting and bending copper sheets, such as... Figure 3As shown, it has a three-fold segment 21 that wraps around the protruding pillars from bottom to top, and electrode pads 22 that fold in opposite directions at both ends. Coils corresponding to the number of slot groups are positioned one-to-one and pre-installed in the slots, and a set of magnetic cores are flush-mounted and wrapped around the coils in the opposite direction of the protruding pillars. As the basis for the inductor's connection to the PCB, the electrode pads of each set of coils are concentrated and formed on the outer side of the top surface of the magnetic core, protruding and electrically isolated from each other, and soldered together to meet the corresponding PCB wiring design.

[0017] Looking at the details further, the width of the coil in the three-fold segment 21 is half the width of the assembled magnetic core, and the electrode pad 22 extends and widens to be flush with the sidewalls of the assembled magnetic core at both ends. That is, the cut copper sheet is narrow in the middle and wide at both ends, continuously bent into a U-shape in the middle in a three-fold segment. Here, the forming structure of this electrode pad allows for direct soldering of compact PCB cables over the electrode pad surface when the inductor is mounted facing the PCB, or for soldering to the ends of the electrode pad to accommodate more sparse cable connections.

[0018] The flattened thickness (i.e., copper sheet thickness) of coil 2 is smaller than the slot opening diameter. Therefore, when pre-installed facing the magnetic core, the coil rests on the top surface 1e of the magnetic core only through the electrode pads. The three-fold segment 21 of the coil is assembled with the slot 11 and the bottom of the protrusion 13 with a clearance fit. In practice, the bottom surface of the coil is recessed inwards relative to the bottom surface of the magnetic core. Simultaneously, the spacing g between the two slots in each group is the same as or close to the group spacing h of each group of slots. The actual width of the electrode pads after bending is approximately one-third of the group spacing h, thus leaving sufficient insulation space between the electrode pads formed by the folding of adjacent coil groups.

[0019] Furthermore, the aforementioned magnetic core 1 is a cold-pressed form of powder material based on a custom mold. It can be a manganese-zinc ferrite core with a working frequency of up to 3MHz and lower core loss, or it can be an alloy core made of one or more of Fe-based / FeSi / FeSiCr / FeSiAl / FeNi / amorphous or nanocrystalline materials.

[0020] like Figure 4 As shown in the schematic diagram of the complete manufacturing process of the preferred embodiment (four groups) of the inductor: First, each group of magnetic cores and coils is prefabricated according to the structural shape and size specifications. Then, each group of coils is pre-installed into the slots of one of the magnetic cores, at which point half of each group of coils will be exposed. Then, adhesive is applied to the outer end face of the side wall 1d of the magnetic core between each group of coils and the outer end face of the protrusion. Another magnetic core is used to align the exposed parts of each group of coils, and they are then attached to the front magnetic core and aligned with the edges before being cold-pressed for shaping. If necessary, insulating varnish can be applied by roller spraying, and localized varnish stripping and electroplating treatment can be performed on the electrode pads to obtain the finished product.

[0021] As can be seen from the detailed description of the preferred embodiment of the multiphase inductor of this utility model, compared with the prior art, its technical effects are as follows: by optimizing the coil structure and multiplexing multiple groups, and designing an assembly structure with multiple slots and multiple coil integration, it helps to reduce the space occupied by the inductor in high-density PCB components and the interference to the surrounding environment, and promotes the performance improvement of switch-mode power supplies in application scenarios such as servers / data centers.

[0022] 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 multiphase inductor, characterized in that: The inductor is assembled from a pre-formed array of coils and a set of magnetic cores. The magnetic core body is formed into a rectangular block, and the sidewalls in three directions of the magnetic core are flat. The remaining long strip sidewall has array slots in pairs that extend through the top and bottom. The bottom of the protrusion formed between each set of slots of the magnetic core is recessed by the opening diameter of one slot. Any set of coils with the same shape has a three-fold section that wraps around the protrusion from bottom to top and electrode pads that are folded in opposite directions at both ends. The coil is positioned in the slot and a set of magnetic cores are glued and wrapped around the coil in the opposite direction of the protrusion.

2. The multiphase inductor according to claim 1, characterized in that: The width of the coil in the three-fold section is half the width of the assembled magnetic core, and the electrode pads extend and widen to be flush with the sidewalls of the assembled magnetic core at both ends.

3. The multiphase inductor according to claim 1, characterized in that: The flattened thickness of the coil is less than the slot opening diameter, and the coil is attached to the top surface of the magnetic core only by the electrode pads. The three folds of the coil are assembled with the slot and the bottom of the protrusion with clearance fit.

4. The multiphase inductor according to claim 1, characterized in that: The magnetic core is a cold-pressed material formed from powder material using a custom mold.

5. The multiphase inductor according to claim 1, characterized in that: The spacing between the two slots in each group is the same as or close to the spacing between the groups of slots, and the insulation gap is left between the electrode pads formed by the folding of the adjacent two groups of coils.

6. The multiphase inductor according to claim 1, characterized in that: The inductor is assembled from four pre-formed coils and one magnetic core. The magnetic core is a rectangular block cold-pressed from powder material using a custom mold. The sidewalls of the magnetic core are flat on three sides, and the remaining elongated sidewall has four sets of slots arranged in pairs, extending through the top and bottom. The bottom of the protrusion formed between each set of slots on the magnetic core is recessed by the diameter of one slot. The spacing between the two slots in each set is the same as the spacing between the sets of slots. Each set of coils of the same shape has a three-fold section that wraps around the protrusion from bottom to top, and two ends. Electrode pads fold in opposite directions, coils are positioned in slots, and a set of magnetic cores are bonded and wrapped together with the opposite protrusions. The width of the coil in the three-fold section is half the width of the assembled magnetic core, and the electrode pads extend and widen to be flush with the side walls of the assembled magnetic core at both ends. The flattened thickness of the coil is less than the slot opening diameter, and the coil is attached to the top surface of the magnetic core only by the electrode pads. The three-fold section of the coil is assembled with the slot and the bottom of the protrusions with clearance. An insulating gap is left between the electrode pads formed by the folding of two adjacent sets of coils.

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