An inductor for vertical power module energization

Abstract

This invention discloses an inductor for vertically energizing a power module. It is assembled and thermoformed from prefabricated E-type magnetic cores, C-type magnetic cores, C-type coils, and I-type coils. The C-type magnetic core is a rectangular block with a vertical slot running through its top and bottom along one long sidewall. The E-type magnetic core is also a rectangular block with two spaced grooves with protruding pillars along one long sidewall. These grooves extend bidirectionally to the top and bottom surfaces of the E-type magnetic core, and the outer contours of the long sidewalls of the two magnetic cores overlap. The I-type coil is assembled into the vertical slot to form a first pre-assembled body. Two C-type coils are assembled one-to-one into the grooves to form a second pre-assembled body. The two pre-assembled bodies are joined flush and thermoformed into a single unit. Electrode pads for both types of coils are distributed on the top and bottom surfaces of the thermoformed body. This inductor simplifies the core and coil assembly structure, providing convenience for direct soldering between upper and lower PCBs in multi-layer PCB applications, and effectively saves space in the power module.

Description

Technical Field

[0001] This utility model relates to an inductor, and more particularly to an inductor for vertical energization of a power module, 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] In high-density PCBs, the number of components and the space occupied are key concerns, especially given the current widespread use of multi-layer PCB stacked architectures in electronic circuit design. When inductors are used to achieve desired circuit functions between upper and lower PCBs, most inductors present challenges in wiring, with some requiring external leads to connect the downward-facing electrode contacts upwards, further complicating PCB assembly. Therefore, improving the vertical current-carrying connection structure of inductors has become a crucial technological gap that urgently needs to be filled in the industry. Summary of the Invention

[0004] In view of the above-mentioned defects in the existing technology, the purpose of this utility model is to propose an inductor for vertical power supply of a power module. By optimizing the internal structure of the device, the inductor can be installed in a multi-layer PCB, saving the overall assembly space of the power module.

[0005] The technical solution of this utility model to achieve the above-mentioned objective is an inductor for vertical power supply of a power module, characterized in that: the inductor is assembled and hot-pressed from prefabricated E-type magnetic cores, C-type magnetic cores, C-type coils and I-type coils, wherein the C-type magnetic core is a rectangular block with a vertical groove penetrating from top to bottom on one long side wall, the E-type magnetic core is a rectangular block with two mutually spaced grooves with protruding pillars on one long side wall, the grooves extending bidirectionally to the top and bottom surfaces of the E-type magnetic core, and the outer contours of the long side walls of the two magnetic cores overlap, the I-type coil is assembled into the vertical groove to form a first pre-assembled body, the two C-type coils are assembled one-to-one into the grooves to form a second pre-assembled body, the two pre-assembled bodies are joined together at the edges and hot-pressed into one piece, and the two types of coils are distributed and formed into electrode pads on the top and bottom surfaces of the hot-pressed body.

[0006] Furthermore, the type I coil is a rectangular prism copper block, and the height of the copper block is consistent with the thickness of the type C magnetic core.

[0007] Furthermore, the C-type coil is based on a flattened copper column in the middle section of the I-type coil, and the height of the copper column is consistent with the thickness of the E-type magnetic core, and the height of the concave part in the middle of the copper column is consistent with the height of the protruding column provided in the E-type magnetic core.

[0008] Furthermore, both the E-type magnetic core and the C-type magnetic core are cold-pressed bodies made of powder material based on a customized mold.

[0009] Furthermore, the surface of the hot-pressed molded body is provided with an insulating coating formed by roller spraying, and the top and bottom surfaces are subjected to paint stripping electroplating treatment corresponding to the ends of each coil, forming electrode pads for corresponding layered PCB assembly.

[0010] Compared with existing technologies, the optimized inductor structure of this invention offers the following advantages: It simplifies the forming and assembly of the magnetic core and coil, and allows for the optional integration of multiple inductors into a single unit. Furthermore, the coil ends are located on both the top and bottom surfaces, providing convenience for direct soldering of the inductor to the upper and lower PCBs in multi-layer PCBs, effectively saving space in power modules. This allows for better application in hardware manufacturing in popular industries such as AI, data centers, autonomous driving, and smart scenarios. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the structure of the E-type magnetic core of the inductor of this utility model.

[0012] Figure 2 This is a schematic diagram of the C-type magnetic core of the inductor of this utility model.

[0013] Figure 3 This is a schematic diagram of the C-type coil of the inductor of this utility model.

[0014] Figure 4 This is a schematic diagram of the structure of the Type I coil of the inductor of this utility model.

[0015] Figure 5 This is a schematic diagram of the assembly, packaging, and finished product process of the inductor of this utility model. Detailed Implementation

[0016] 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. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present application.

[0017] The designer of this utility model aimed to facilitate the insertion and soldering of inductors between layers in multilayer PCB applications, and to save the overall space occupied by the power module. Key innovative features include... Figures 1 to 4 As shown, the inductor is assembled and hot-pressed from prefabricated E-type magnetic core 1, C-type magnetic core 2, C-type coil 3, and I-type coil 4. In terms of appearance, the C-type magnetic core 2 is a rectangular block with a vertical groove 22 extending through the top and bottom on one long sidewall 21. The other sidewalls of this C-type magnetic core are smooth planes. The E-type magnetic core 1 is also a rectangular block with two spaced grooves 12 with protrusions 13 on one long sidewall 11. Similarly, the other sidewalls of this E-type magnetic core are smooth planes. The grooves 12 extend bidirectionally to the top and bottom surfaces of the E-type magnetic core, and the outer contours of the long sidewalls of the two cores overlap. The I-type coil is assembled into the vertical groove to form a first pre-assembled body A, and the two C-type coils are assembled one-to-one into the grooves to form a second pre-assembled body B. The two pre-assembled bodies are joined at the edges and hot-pressed into a single unit. Electrode pads for both types of coils are distributed and formed on the top and bottom surfaces of the hot-pressed body. In this way, when the height of the inductor is matched with the spacing between the upper and lower PCB layers, the inductor can be smoothly inserted between the two boards and its electrode pads are aligned with the electrode contacts on the circuit board to complete the soldering.

[0018] As can be seen from the inductor structure outlined above, for the first pre-mounted body A, the illustrated embodiment only has a single vertical slot and pre-mounts one type I coil. If necessary, two separate vertical slots can also be provided and two type I coils can be pre-mounted. For the second pre-mounted body B, the illustrated embodiment has two grooves and pre-mounts two type C coils. In feasible implementations, one or more grooves can also be provided, corresponding to the pre-mounting of a corresponding number of type C coils. Moreover, in addition to the illustrated embodiment, the splicing direction of the first pre-mounted body A and the second pre-mounted body B can also be selected such that the second pre-mounted body B comes first and the first pre-mounted body A comes last. In this way, the two types of coils will be isolated by the ungrooved part of the magnetic core that comes first, reducing the coupling interference between the coils.

[0019] Looking at the details further, the aforementioned Type I coil 4 is a rectangular copper block, and the height h1 of the copper block is the same as the thickness d1 of the Type C magnetic core 2. The aforementioned Type C coil 3 is a copper column flattened from the middle section of the Type I coil, and the height h2 of the copper column is the same as the thickness d2 of the Type E magnetic core 1, while the height h3 of the concave part in the middle of the copper column is the same as the height of the protrusion 13 provided in the Type E magnetic core.

[0020] Both the aforementioned Type E magnetic core 1 and Type C magnetic core 2 are cold-pressed bodies made of magnetic powder using a custom mold. The magnetic powder used is one or a mixture of two or more of Fe-based, FeSiAl, FeNi, FeSiCr, FeSi, amorphous or nanocrystalline materials, with epoxy resin, silicone resin or acrylic resin selectively added, and the cold pressing pressure is between 6 Tons / cm² and 12 Tons / cm².

[0021] After the aforementioned thermo-pressed rectangular block is produced, it needs to undergo surface painting to form an insulating coating. Additionally, the outer surfaces of the top and bottom surfaces corresponding to the ends of the two types of coils are partially stripped of paint and electroplated to form electrode pads, thus creating a separation distance between them to facilitate assembly and soldering within a layered PCB circuit board.

[0022] The above structural description of the inductor used for vertical energization of the power module provides further insight into its manufacturing process. For example... Figure 5 The process is briefly described below: S1. Pre-fabrication: Based on the specifications and dimensions, a first mold corresponding to the E-type magnetic core and a second mold corresponding to the C-type magnetic core are prefabricated. Then, magnetic powder is filled into both molds and molded to obtain individual parts. Square-section copper strips are taken and cut to length specifications to obtain I-type coils. A portion of these is then processed in a stamping fixture to obtain C-type coils, resulting in batch prefabricated parts for the four components.

[0023] S2. Take a C-type magnetic core 2 and an I-type coil 4, and pre-assemble them to obtain the first pre-assembled body A. Take an E-type magnetic core 1 and two C-type coils, and pre-assemble them to obtain the second pre-assembled body B. Here, the pre-assembly between the two types of magnetic cores and the corresponding two types of coils does not involve a mandatory fixed connection, but only a movable contact between them.

[0024] S3. The two pre-assembled bodies are joined together at the edges and transferred to a pre-made molding mold of the corresponding size and specifications for hot pressing and sealing. Then, the solidified block C is obtained by baking. Here, during hot pressing and sealing, it is also necessary to add a suitable amount of hot pressing powder to fill the gaps formed by the pre-assembly and cover the surface. The hot pressing powder is one or more of Fe-based, FeSiAl, FeNi, FeSiCr, amorphous or nanocrystalline materials, and is uniformly mixed with epoxy resin, silicone resin or acrylic resin. The sealing parameters include a molding temperature between 100~200℃, a molding pressure between 4Tons / cm²~12Tons / cm², and a molding time of 30-180sec.

[0025] S4. Spray paint the cured block C obtained in S3 to obtain a semi-finished product D covered with an insulating coating. Laser paint stripping and electroplating are performed on the ends of the two coils to form electrode pads 41 corresponding to the type I coil and electrode pads 32 corresponding to the type C coil. There are also corresponding electrode pads at the corresponding positions on the bottom surface (not shown). In other words, in the finished inductor E, each coil is directly welded to the top and bottom and is in a vertical energized state when working.

[0026] In summary, the above introduction and detailed embodiments of the inductor for vertically energized power modules demonstrate that, compared to existing technologies, this solution possesses substantial features and advancements. Its technical advantages include: simplified core and coil forming and assembly structure; optional integration of multiple inductors into a single unit; and the placement of each coil end on both the top and bottom surfaces, providing convenience for direct soldering of the inductor to the upper and lower PCBs in multi-layer PCBs, effectively saving space in the power module. This allows for better application in hardware manufacturing in popular industries such as AI, data centers, autonomous driving, and smart scenarios.

[0027] 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. An inductor for vertical power module power-up, characterized by: The inductor is assembled and hot-pressed from prefabricated E-type magnetic cores, C-type magnetic cores, C-type coils, and I-type coils. The C-type magnetic core is a rectangular block with a vertical groove that runs through the top and bottom on one long side wall. The E-type magnetic core is a rectangular block with two spaced grooves with protruding pillars on one long side wall. The grooves extend bidirectionally to the top and bottom surfaces of the E-type magnetic core, and the outer contours of the long side walls of the two magnetic cores overlap. The I-type coil is assembled into the vertical groove to form a first pre-assembled body. Two C-type coils are assembled one-to-one into the grooves to form a second pre-assembled body. The two pre-assembled bodies are joined together at the edges and hot-pressed into one piece. The two types of coils are distributed and formed into electrode pads on the top and bottom surfaces of the hot-pressed body.

2. The inductor for vertical power-on of a power module of claim 1, wherein: The type I coil is a rectangular copper block, and the height of the copper block is the same as the thickness of the type C magnetic core.

3. The inductor for vertical power-on of a power module of claim 1, wherein: The C-type coil is based on a flattened copper column in the middle section of the I-type coil, and the height of the copper column is the same as the thickness of the E-type magnetic core. The height of the concave part in the middle of the copper column is the same as the height of the protruding column in the E-type magnetic core.

4. The inductor for vertical power-on of a power module of claim 1, wherein: Both the E-type and C-type magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

5. The inductor for vertical power-on of a power module of claim 1, wherein: The surface of the hot-pressed molded body is provided with an insulating coating formed by roller spraying, and the top and bottom surfaces are subjected to paint stripping electroplating treatment corresponding to the ends of each coil, forming electrode pads 2 for corresponding layered PCB assembly.

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