A four-phase uncoupled TLVR inductor

Abstract

This invention discloses a four-phase uncoupled TLVR inductor, assembled from several prefabricated primary coils, secondary coils, two twin magnetic cores, and a plate magnetic core. Each twin magnetic core is formed into a rectangular block with a first slot, a partition wall, and a second slot distributed along its length. A first protrusion sharing a bottom surface is formed in the first slot, and a second protrusion sharing a bottom surface is formed in the second slot. The secondary coil is bent into a closed-loop annular body that wraps around any protrusion. The primary coil is bent into an open-loop annular body that wraps around the secondary coil and fits into the corresponding slot. The two prefabricated bodies are arranged side by side in the same direction and flush with the edge of the plate magnetic core, and then heat-pressed into a single unit. The exposed portions of all coils are concentrated at the bottom of the formed magnetic core and formed into insulating electrode pads. This inductor is beneficial for improving the insulation isolation between the four-phase two-stage coils and optimizing the coupling efficiency between phases, and also achieves better transient response under low duty cycle conditions.

Description

Technical Field

[0001] This utility model relates to an inductor, and more particularly to a four-phase uncoupled TLVR 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] The TLVR (Trans-Inductor Voltage Regulator) architecture is a newly developed VR (Voltage Regulator) power supply architecture in recent years. Its biggest difference from the traditional DC to DCBuck and DC (DC) architectures is that it replaces the traditional single-wound ordinary inductor with a TLVR inductor that has two windings and is similar to a transformer. Ordinary inductors have only one set of windings with two pins, while TLVR inductors have two sets of mutually coupled windings with four pins. The two have a great difference in structure.

[0004] Currently, when designing the structure of TLVR inductors, the number of components and the space occupied in high-density PCBs are key concerns in the industry. Therefore, optimizing the integration of multiple TLVR inductors within limited space and the coupling coefficient has become a crucial technological gap that the industry urgently needs to fill. Summary of the Invention

[0005] In view of the above-mentioned defects in the existing technology, the purpose of this utility model is to propose a four-phase uncoupled TLVR inductor, which reduces the space occupied by multi-phase integrated devices and improves the performance of the finished product by optimizing the internal structure of the device.

[0006] The technical solution of this utility model to achieve the above-mentioned objective is a four-phase uncoupled TLVR inductor, which is assembled from a number of prefabricated primary coils, secondary coils, two twin magnetic cores and a plate magnetic core. Each twin magnetic core is formed into a rectangular block. The top surface and one side wall of the twin magnetic core are flat, and the other side wall is provided with a first groove, a partition wall and a second groove distributed along the length direction. A first protrusion with a shared bottom surface is formed in the first groove, and a second protrusion with a shared bottom surface is formed in the second groove. The secondary coil is bent into a closed ring shape that wraps around any protrusion. The primary coil is bent into an open ring shape that wraps around the secondary coil and is accommodated in the corresponding groove. One twin magnetic core and two sets of primary coils and two sets of secondary coils are assembled into a pre-assembled body. The two pre-assembled bodies are arranged side by side in the same direction and flush with the edge of the plate magnetic core and hot-pressed into a whole. The exposed parts of all coils are concentrated at the bottom of the formed magnetic core and formed into an insulating electrode pad.

[0007] Furthermore, the first and second cavities have the same shape and dimensions, and the depth d of each cavity is the difference between the width w of the twin cores and the thickness t of the sheet core.

[0008] Furthermore, the primary coil is formed by continuously bending a flat copper strip, and has a wide-bottomed U-shaped three-fold segment and outward-folded wings at both ends. Each slot has a gradient arc surface at both ends that matches the shape of the outward-folded wings and is positioned in the center.

[0009] Furthermore, the secondary coil is formed by continuously bending flat enameled wire in the same direction into a rectangular ring with an opening, and the secondary coil is fitted around any protruding post with the opening fitting against the bottom surface of the protruding post.

[0010] Furthermore, the thickness of the primary coil is greater than that of the secondary coil, and the DC resistance ratio of the secondary coil to the primary coil is between 3 and 5; in the packaged state, the insulation isolation between the two coils is maintained above DC 150V.

[0011] Furthermore, the lateral profile of the plate core coincides with the lateral profile of the twin core.

[0012] Furthermore, both the twin magnetic cores and the sheet magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

[0013] Furthermore, the surface of the semi-finished product formed by hot pressing is provided with an insulating coating formed by roller spraying, and the exposed part at the bottom of the formed magnetic core corresponding to the two-stage coil is subjected to paint peeling and electroplating treatment to form electrode pads for PCB assembly.

[0014] Compared with existing technologies, the advantages of the TLVR inductor of this invention are as follows: This inductor adopts an integrated structure combining twin magnetic cores and multiple sets of two-stage coils, along with a chip core thermoforming package. This facilitates stable thermoforming of the assembly, improves insulation isolation and coupling efficiency between the four-phase two-stage coils, and enhances the transient response of this type of inductor. Therefore, it can be better applied in hardware manufacturing for popular industries such as AI, data centers, autonomous driving, and smart scenarios. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the primary coil of the TLVR inductor of this utility model.

[0016] Figure 2 This is a schematic diagram of the secondary coil of the TLVR inductor of this utility model.

[0017] Figure 3 This is a schematic diagram of the twin magnetic cores of the TLVR inductor of this utility model.

[0018] Figure 4 This is a schematic diagram of the chip core of the TLVR inductor of this utility model.

[0019] Figure 5 This is a schematic diagram of the assembly, packaging, and finished product process of the TLVR inductor of this utility model.

[0020] Figure 6 The coupling rate result of the TLVR inductor of this utility model is obtained through simulation. Detailed Implementation

[0021] 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 of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0022] To reduce the space occupied by finished inductors in high-density PCBs, the designers of this utility model focused on optimizing the internal structure of the inductor. Key innovative features include... Figures 1 to 4As shown, the four-phase uncoupled TLVR inductor is assembled from several prefabricated primary coils 1, secondary coils 2, two twin magnetic cores 3, and a plate magnetic core 4. From the external appearance, any one of the twin magnetic cores 3 is integrally molded into a rectangular block. The top surface 3c and one side wall 3a of the twin magnetic core are flat, and the other side wall 3b has a first receiving groove 31, a partition column wall 33, and a second receiving groove 32 distributed along the length direction. A first protrusion 34 sharing a bottom surface is formed in the first receiving groove 31, and a second protrusion 35 sharing a bottom surface is formed in the second receiving groove 32. The lateral profile of the plate magnetic core 4 coincides with the lateral profile of the twin magnetic cores. The secondary coil 2 is bent into a closed-loop ring shape that wraps around any protrusion, and the primary coil 1 is bent into an open-loop ring shape that wraps around the secondary coil 2 and is accommodated in the corresponding receiving groove. Based on the above-mentioned forming of each part, the aforementioned twin magnetic core 3, two sets of primary coils 1, and two sets of secondary coils 2 are assembled into a pre-assembled body. The two pre-assembled bodies are arranged side by side in the same direction and flush with the edge of the plate magnetic core, and then heat-pressed and packaged into one piece. All exposed parts of the coils are concentrated at the bottom of the formed magnetic core and formed into insulating and isolated electrode pads.

[0023] As can be seen from the inductor structure outlined above, for one pre-assembled unit, the two sets of primary and secondary coils are isolated by partition columns, and each set of primary and secondary coils is electrically isolated from each other. For the assembled unit, one side wall 3a of the two twin magnetic cores and the plate magnetic core form a shell and intermediate isolation for four sets of primary and secondary coils. This results in four-phase primary and secondary coils that achieve reliable isolation while being integrated into a single device, thereby minimizing mutual coupling interference, achieving a coupling coefficient k < 0.1, and improving the coupling coefficient of each phase's primary and secondary coils.

[0024] Looking at the details further, the first and second troughs 31 and 32 have the same shape and dimensions, and the depth d of each trough is the difference between the width w of the twin magnetic cores and the thickness t of the sheet magnetic core. Therefore, the thickness of the outer casing and the intermediate separator are the same.

[0025] The aforementioned primary coil 1 is formed by continuously bending a flat copper strip, featuring a wide-bottomed U-shaped three-fold segment 11 and outward-flared flaps 12 at both ends. For example... Figure 1 As shown, due to the relatively thick flat copper strip, the outward-folding wing is roughly curved. Correspondingly, each slot has a gradually curved surface at both ends that matches the shape of the outward-folding wing and is positioned in the center. Taking the first slot 31 as an example, the gradually curved surface at one end engages with the partition wall but does not reach the bottom surface 3d of the twin cores, while the gradually curved surface at the other end extends outward, creating a notch on the left side wall 3e of the twin cores (the second slot corresponds to the right side wall 3f). This allows the primary coil to be laterally moved and inserted into the slot.

[0026] The aforementioned secondary coil 2 is formed by continuously bending flat enameled wire in the same direction into a rectangular ring with an opening 21. The secondary coil is fitted around any protruding post, with the opening fitting against the bottom surface of the protruding post. Since the protruding post shares a bottom surface with the twin core, the opening of the secondary coil and the outward-folding flaps of the aforementioned primary coil are concentrated on the bottom surface 3d of the twin core. Furthermore, as shown in the figure, the thickness of the primary coil 1 is greater than the thickness of the secondary coil 2, and the DC resistance ratio of the secondary coil relative to the primary coil is between 3 and 5 due to the enameled coating. In the packaged state, the insulation between the two coils maintains a DC voltage of over 150V. However, due to the high degree of overlap in the nesting, the coupling coefficient between each set of primary and secondary coils is generally high. See [reference needed]. Figure 6 The simulation results are shown.

[0027] 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 exposed primary and secondary coils are partially stripped of paint and electroplated to form electrode pads, thereby increasing the isolation distance between them to meet the requirements of circuit board soldering and assembly.

[0028] The optimization of the internal structure of this TLVR inductor, as described above, allows for a deeper understanding of 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 twin magnetic cores and a second mold corresponding to the sheet magnetic cores are pre-fabricated. Then, magnetic powder is filled into the two molds and molded to obtain individual parts. Flat copper strips and flat enameled wires are used as materials and pre-fabricated in batches according to the specifications and dimensions to obtain a constricted ring-shaped secondary coil and an open-ring-shaped primary coil.

[0029] S2. Take two twin magnetic cores, four sets of primary coils, and four sets of secondary coils. Take two sets of secondary coils and fit them one-to-one with two protrusions. Then take two sets of primary coils and insert them into the gaps between the slots and the secondary coils to make a pre-assembled body A1. Pre-assemble another pre-assembled body A2 in the same way.

[0030] S3. The two pre-assembled bodies are placed side by side in the same direction and flush with a plate magnetic core, and then hot-pressed and packaged. The solidified block C is obtained by baking.

[0031] S4. Spray paint on the solidified 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 multiple sets of distributed electrode pads (or electrode contacts).

[0032] In implementing the above manufacturing method, the magnetic powder material for the two pre-fabricated magnetic cores in S1 is one or a mixture of two or more of Fe-based, FeSiAl, FeNi, FeSiCr, FeSi, amorphous, or nanocrystalline materials, and epoxy resin, silicone resin, or acrylic resin is selectively added, with the cold pressing molding pressure between 6 Tons / cm² and 10 Tons / cm². In S3, after adding the hot-press encapsulation molding mold, the surface is also appropriately covered with hot-press powder material, which is one or a mixture of two 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 encapsulation parameters include a molding temperature between 100 and 200°C, a molding pressure between 4 Tons / cm² and 12 Tons / cm², and a molding time of 30-180 seconds.

[0033] In summary, the above introduction and detailed description of the four-phase uncoupled TLVR inductor of this utility model demonstrate that, compared with existing technologies, this solution possesses substantial features and advancements. Its technical advantages are manifested in the following ways: This inductor employs a unibody structure combining twin magnetic cores and multiple sets of two-stage coils, coupled with a chip-type magnetic core thermoforming package. This facilitates stable thermoforming of the assembly, improves insulation isolation and coupling efficiency between the four-phase two-stage coils, and enhances the transient response of such inductor devices. Therefore, it can be better applied in hardware manufacturing for popular industries such as AI, data centers, autonomous driving, and smart scenarios.

[0034] 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 four-phase uncoupled TLVR inductor characterized by: The inductor is assembled from several prefabricated primary coils, secondary coils, two twin magnetic cores, and one plate magnetic core. Each twin magnetic core is formed into a rectangular block. The top surface and one side wall of the twin magnetic core are flat, and the other side wall is provided with a first groove, a partition wall, and a second groove distributed along the length direction. A first protrusion sharing a bottom surface is formed in the first groove, and a second protrusion sharing a bottom surface is formed in the second groove. The secondary coil is bent into a closed-loop ring that wraps around any protrusion. The primary coil is bent into an open-loop ring that wraps around the secondary coil and fits into the corresponding groove. One twin magnetic core, two sets of primary coils, and two sets of secondary coils are assembled into a pre-assembled body. The two pre-assembled bodies are arranged side by side in the same direction and flush with the edge of the plate magnetic core, and are heat-pressed and sealed into one piece. The exposed parts of all coils are concentrated at the bottom of the formed magnetic core and formed into an insulating electrode pad.

2. The four-phase uncoupled TLVR inductor of claim 1, wherein: The first and second cavities have the same shape and dimensions, and the depth d of each cavity is the difference between the width w of the twin cores and the thickness t of the sheet core.

3. The four-phase uncoupled TLVR inductor of claim 1, wherein: The primary coil is formed by continuously bending a flat copper strip, and has a wide-bottomed U-shaped three-fold segment and outward-folded wings at both ends. Each slot has a gradient arc surface at both ends that matches the shape of the outward-folded wings and is positioned in the center.

4. The four-phase uncoupled TLVR inductor of claim 1, wherein: The secondary coil is formed by continuously bending flat enameled wire in the same direction into a rectangular ring with an opening, and the secondary coil is fitted around any protruding post with the opening fitting against the bottom surface of the protruding post.

5. The four-phase uncoupled TLVR inductor of claim 1, wherein: The thickness of the primary coil is greater than that of the secondary coil, and the DC resistance ratio of the secondary coil to the primary coil is between 3 and 5; the insulation isolation between the two coils in the packaged state is maintained above DC 150V.

6. The four-phase uncoupled TLVR inductor of claim 1, wherein: The lateral profile of the plate core coincides with the lateral profile of the twin core.

7. The four-phase uncoupled TLVR inductor of claim 1, wherein: Both the twin magnetic cores and the sheet magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

8. The four-phase uncoupled TLVR inductor of claim 1, wherein: The surface of the semi-finished product formed by hot pressing is coated with an insulating coating formed by roller spraying, and the exposed part of the bottom of the formed magnetic core corresponding to the two-stage coil is subjected to paint peeling and electroplating treatment to form the electrode pads corresponding to the PCB assembly.

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