Hot pressed tlvr inductor

Abstract

The utility model discloses a kind of hot-press TLVR inductors, by primary magnetic core, primary coil, secondary magnetic core and secondary coil combination form, wherein primary coil is assembled in primary magnetic core and two ends are uprightly bent upwards, form primary assembly, secondary coil is assembled in secondary magnetic core and two ends are continuously bent and present open type package, form secondary assembly, this secondary magnetic core is assembled on primary magnetic core and the two ends of primary coil sandwich secondary coil and hide in secondary magnetic core, by two-stage assembly hot-press forming package, and two-stage coil is formed as four electrode pads on the same side of package.The hot-press TLVR inductor realizes double inductance integration by optimizing the preform shape of two magnetic cores and coils, and effectively saves the space occupied in PCB;And in the application of server power supply circuit, the conversion efficiency of TLVR inductor is improved, thereby facilitating the development of hardware performance in artificial intelligence AI server / data center / automatic driving and other application scenarios.

Description

Technical Field

[0001] This utility model relates to an inductor device, and more particularly to a hot-pressed TLVR inductor that improves circuit conversion efficiency and saves space occupied by the 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, most inductors in the industry, after structural design and production, have shown that circuit conversion efficiency needs improvement. At the same time, the shape and footprint of inductor devices are also key considerations for circuit designers. Inductor products need to seek breakthroughs in all aspects, including stable performance parameters, reduced space occupation, and ease of installation. Summary of the Invention

[0005] The purpose of this invention is to propose a hot-pressed TLVR inductor to improve the functionality of circuit applications.

[0006] The technical solution of this utility model to achieve the above-mentioned objective is: a hot-pressed TLVR inductor, which is formed by assembling a primary magnetic core, a primary coil, a secondary magnetic core, and a secondary coil. The primary coil is assembled in the primary magnetic core and bent vertically upwards at both ends to form a primary assembly. The secondary coil is assembled in the secondary magnetic core and bent continuously at both ends to form an open-type wrapping to form a secondary assembly. The secondary magnetic core is positioned and assembled on the primary magnetic core, and the two ends of the primary coil sandwich the secondary coil and hide it in the secondary magnetic core. The two assemblies are hot-pressed to form a package, and the two coils are formed into four electrode pads on the same side of the package.

[0007] Furthermore, the primary magnetic core and the secondary magnetic core are formed into two strip-shaped blocks with the same length and width. The upper surface of the primary magnetic core is provided with a linear groove for the primary coil to be embedded therein, and both ends of the secondary magnetic core are provided with grooves that open outward and are used to wrap and position the secondary coil.

[0008] Furthermore, both the primary and secondary magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

[0009] Furthermore, the primary coil is made of copper strip bent into a wide-bottomed U-shape and its surface is fully covered with an insulating layer.

[0010] Furthermore, the secondary coil is formed by continuously bending and wrapping flat enameled wire around the secondary coil.

[0011] Furthermore, the surface of the package is covered with a fully insulating varnish, and the bottom of the package is partially stripped of the varnish and electroplated to form electrode pads.

[0012] Compared with existing technologies, the advantages of this hot-pressed TLVR inductor are as follows: by optimizing the prefabricated shape of the two magnetic cores and coils, dual inductors are integrated into the same device, effectively saving space on the PCB; and in the application of server power circuits, the conversion efficiency of the TLVR inductor is improved, which is conducive to promoting the development of hardware performance in application scenarios such as artificial intelligence servers / data centers / autonomous driving. Attached Figure Description

[0013] Figure 1 This is a close-up structural diagram of the primary magnetic core in the hot-pressed TLVR inductor of this utility model.

[0014] Figure 2 This is a schematic diagram of the molding structure of the primary coil in the hot-pressed TLVR inductor of this utility model.

[0015] Figure 3 This is a close-up structural diagram of the secondary magnetic core in the hot-pressed TLVR inductor of this utility model.

[0016] Figure 4 This is a schematic diagram of the molding structure of the secondary coil in the hot-pressed TLVR inductor of this utility model.

[0017] Figure 5 This is a schematic diagram showing the evolution of the external shape of the hot-pressed TLVR inductor according to a preferred embodiment of this utility model. Detailed Implementation

[0018] 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.

[0019] This utility model proposes a hot-pressed TLVR inductor, such as Figures 1 to 5 As shown, the basic structure of this inductor consists of a pre-formed primary magnetic core 1, a primary coil 2, a secondary magnetic core 3, and a secondary coil 4, and is obtained through a series of manufacturing processes including thermoforming, painting, partial paint stripping, and electroplating. In summary, the primary coil 2 is assembled within the primary magnetic core 1 with both ends bent upwards, forming the primary assembly A. The secondary coil 4 is assembled within the secondary magnetic core 3 with both ends continuously bent into an open shape, forming the secondary assembly B. The secondary magnetic core 3 is positioned on the primary magnetic core 1, with the ends of the primary coil 2 sandwiching the secondary coil 4 and concealing it within the secondary magnetic core 3. The two assemblies are then thermoformed into a package. This independent device is then used in subsequent routine processes as the basis for connecting the inductor to the PCB, resulting in four electrode pads formed on the same side of the package. The finished inductor has a smooth surface except for the bottom surface, and is arranged vertically. When assembling for circuit application, only the bottom surface where the electrode pads are located faces downwards, and the two contacts corresponding to the secondary coil are connected by vertical pressure welding, while the two contacts corresponding to the primary coil are connected by visible side spot welding.

[0020] The structural features and assembly distribution of the aforementioned components will be detailed below, and both the two-stage magnetic core and the coil can be prefabricated and reused in batches. Based on the overview of this technical solution and the illustrations of preferred embodiments, the detailed features of each functional component of this inductor also include: Figure 1 and Figure 3 As shown, the primary magnetic core 1 and the secondary magnetic core 3 are formed into two strip-shaped blocks with the same length and width, so that they can be joined together at the same edge. In particular, the upper surface of the primary magnetic core 1 has a linear groove 11 for the primary coil to be embedded therein, while the two ends of the secondary magnetic core 3 have outward-facing grooves 31, which provide a place for the secondary coil to be wrapped and positioned. Here, the depth of the groove is greater than the sum of the thicknesses of the two coils. Both magnetic cores are prefabricated assemblies based on powder materials and customized molds. The mass prefabrication of both uses a cold pressing process. The powder material used for the magnetic core can be one or more of Fe-based / FeSiCr / FeSiAl / FeNi / FeSi / amorphous / nanocrystalline materials, and one of epoxy resin, silicone resin or acrylic resin is added and stirred evenly before being injected into a customized mold that conforms to the shape of the device. The molding pressure range is 6-12 Tons / cm².

[0021] like Figure 2 and Figure 4As shown, the primary coil 2 is formed by bending a copper strip into a wide-bottomed U-shape and fully covering its surface with an insulating layer. Its two ends are bent upwards to form an upright portion 21. The secondary coil 4 is formed by continuously bending and wrapping a flat enameled wire around the secondary coil to form a mating portion 41. Since both coils are insulated, they are not electrically connected even though the upright portion surrounds the mating portion. Specifically, to enhance the electrical isolation between the two coils after forming the electrode pads, the secondary coil is rounded when wrapping the secondary core, which facilitates separation from the primary coil after thermoforming.

[0022] like Figure 5 As shown in the diagram, the complete manufacturing process of the preferred embodiment of the hot-pressed TLVR inductor is as follows: First, two-stage magnetic cores and two-stage coils are prefabricated in batches according to shape and specification requirements, with a batch ratio of 1:1:2. Here, the magnetic cores are manufactured by cold pressing after filling a mold with relevant powder material, as described above. The coil manufacturing method is slightly different. The primary coil is directly formed into a wide-bottomed U-shaped fixed shape, while the secondary coil is partially bent into a shape to be wrapped. Then, the primary assembly A and the secondary assembly B are prepared in no particular order. As can be seen from the diagram, both assemblies are symmetrical from left to right, so that the outer contours of the two magnetic cores can overlap when they are stacked together. The assembly is then transferred into a corresponding mold for thermoforming, and the gap between the assembly and the inner wall of the thermoforming mold is filled with one or more mixtures of Fe-based / FeNi / FeSiAl / amorphous or nanocrystalline materials. It is then held at a molding temperature range of 100-200℃ and a molding pressure of 4-12 Tons / cm² for 30-180 seconds to obtain a thermoformed package C. After cooling, the package C undergoes a painting process to fully cover its surface with an insulating enamel film 5, resulting in an enamel-coated body D. Partial enamel stripping is then performed to partially expose the vertical portion 21 of the primary coil and the mating portion 41 of the secondary coil, resulting in an electroplating pre-body E. Finally, electroplating is used to form the four parallel-separated solder pads 6 on the bottom surface of the TLVR inductor. The finished inductor devices undergo external inspection, testing, quality inspection, packaging, and shipment sequentially.

[0023] In summary, the preferred embodiment of the hot-pressed TLVR inductor of this utility model, as detailed above, demonstrates the following technical advantages compared to existing technologies: by optimizing the prefabricated shape of the two magnetic cores and the coil, dual inductors are integrated into the same device, effectively saving space on the PCB; and in server power circuit applications, the conversion efficiency of the TLVR inductor is improved, thereby promoting the development of hardware performance in application scenarios such as AI servers, data centers, and autonomous driving.

[0024] 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 hot-pressed TLVR inductor, characterized in that: The inductor is formed by assembling a primary magnetic core, a primary coil, a secondary magnetic core, and a secondary coil. The primary coil is assembled in the primary magnetic core and bent vertically upwards at both ends to form a primary assembly. The secondary coil is assembled in the secondary magnetic core and bent continuously at both ends to form an open-type enclosure to form a secondary assembly. The secondary magnetic core is positioned and assembled on the primary magnetic core, with the ends of the primary coil sandwiching and hiding the secondary coil within the secondary magnetic core. The two assemblies are thermo-pressed to form a package, and the two coils are formed into four electrode pads on the same side of the package.

2. The hot-pressed TLVR inductor according to claim 1, characterized in that: The primary magnetic core and the secondary magnetic core are formed into two strip-shaped blocks with the same length and width. The upper surface of the primary magnetic core has a linear groove for the primary coil to be embedded therein, and both ends of the secondary magnetic core have grooves with outward openings for the secondary coil to be wrapped and positioned.

3. The hot-pressed TLVR inductor according to claim 1, characterized in that: Both the primary and secondary magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

4. The hot-pressed TLVR inductor according to claim 1, characterized in that: The primary coil is made of copper strips bent into a wide-bottomed U-shape and its surface is fully covered with an insulating layer.

5. The hot-pressed TLVR inductor according to claim 1, characterized in that: The secondary coil is formed by continuously bending and wrapping flat enameled wire around the secondary coil.

6. The hot-pressed TLVR inductor according to claim 1, characterized in that: The surface of the package is covered with a fully insulating varnish, and the bottom of the package is partially stripped of the varnish and electroplated to form electrode pads.

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