A one-piece molded multi-group dual-coil TLVR inductor

Abstract

This invention discloses an integrally molded multi-group dual-coil TLVR inductor. The inductor includes a first magnetic core and a second magnetic core arranged opposite each other, with at least one third magnetic core disposed between the first and second magnetic cores. Coupled dual-coil structures are respectively disposed between the first, second, and third magnetic cores. This invention effectively improves the space utilization and integration level of the TLVR inductor. Furthermore, through a hot-pressing process, the primary and secondary coils are tightly pressed with the first and second E-type magnetic cores and the third magnetic core into a single integrated structure, effectively reducing the inductor volume, lowering power loss, and improving magnetic saturation. Specifically, the product size is reduced by approximately 20%, and the power loss is also reduced by approximately 20%.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and in particular to an integrally molded multi-group dual-coil TLVR inductor. Background Technology

[0002] TLVR inductors, or voltage-regulated dual-coupled inductors, are typically made of Mn-Zn ferrite material with a double-E polarity structure, and then combined with a coupled dual coil.

[0003] Current TLVR inductors all use a dual-coil structure, which has the drawbacks of low space utilization and low integration. Utility Model Content

[0004] The main purpose of this invention is to propose an integrally molded multi-group dual-coil TLVR inductor, which aims to improve the space utilization and integration of TLVR inductors.

[0005] To achieve the above objectives, this utility model provides an integrally molded multi-group dual-coil TLVR inductor, including a first magnetic core and a second magnetic core arranged opposite to each other, at least one third magnetic core disposed between the first magnetic core and the second magnetic core, and a coupled dual-coil structure disposed between the first magnetic core, the second magnetic core and the third magnetic core respectively.

[0006] A further technical solution of this utility model is that the dual-coil structure includes a primary coil and a secondary coil. A positioning block for positioning the secondary coil is provided in the middle of the first magnetic core and the second magnetic core, and in the middle of the front and back surfaces of the third magnetic core. A positioning groove is formed around the positioning block in the middle portion of the first magnetic core and the second magnetic core, and in the middle position of the front and back surfaces of the third magnetic core. The primary coil and the secondary coil are disposed in the positioning groove. An insulating coating is provided on the surface of the secondary coil, and the secondary coil is fitted inside the primary coil.

[0007] A further technical solution of this utility model is that the first magnetic core, the second magnetic core, and the third magnetic core all have E-shaped structures on both sides, i.e., double E-shaped structures, and the positioning groove is U-shaped.

[0008] A further technical solution of this utility model is that strip-shaped limiting posts for limiting the primary coil are respectively provided at both ends of the first magnetic core and the second magnetic core on one side of the positioning groove, and at both ends of the front and back sides of the third magnetic core.

[0009] A further technical solution of this utility model is that the primary coil is U-shaped, and the two free ends of the primary coil extend outward to form a first pin and a second pin.

[0010] A further technical solution of this utility model is that the secondary coil is U-shaped, and the two free ends of the secondary coil extend inward to form a third pin and a fourth pin, and the first pin, the second pin, the third pin and the fourth pin are flush.

[0011] A further technical solution of this utility model is that the materials of the first magnetic core, the second magnetic core and the third magnetic core are iron-nickel alloys or mixed alloys with iron and nickel as the main components.

[0012] The beneficial effects of this utility model of an integrally molded multi-group dual-coil TLVR inductor are:

[0013] This utility model, through the above-described technical solution, includes a first magnetic core and a second magnetic core arranged opposite to each other, with at least one third magnetic core disposed between the first and second magnetic cores. A coupled dual-coil structure is respectively disposed between the first, second, and third magnetic cores, which can effectively improve the space utilization and integration level of the TLVR inductor. Furthermore, this utility model uses a hot-pressing molding process to tightly press the primary and secondary coils with the first, second, and third magnetic cores into a single integrated structure, effectively reducing the inductor volume, lowering power loss, and improving magnetic saturation. Specifically, the product size is reduced by approximately 20%, and the power loss of the product can also be reduced by approximately 20%. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the overall structure of a preferred embodiment of the integrally molded multi-group dual-coil TLVR inductor of this utility model;

[0016] Figure 2 This is a schematic diagram showing the forming of the first, second, and third magnetic cores;

[0017] Figure 3 This is a schematic diagram of the secondary coil.

[0018] Figure 4 This is a schematic diagram of the primary coil.

[0019] Figure 5This is a structural diagram of the first and second E-type magnetic cores;

[0020] Figure 6 This is a schematic diagram of the structure of the third magnetic core of the double-E type.

[0021] Explanation of icon numbers:

[0022] First magnetic core 1; Third magnetic core 2; Primary coil 3; Secondary coil 4; Positioning block 5; Limiting post 6; First pin 7; Second pin 8; Third pin 9; Fourth pin 10.

[0023] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0024] 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.

[0025] This utility model proposes an integrally molded multi-group dual-coil TLVR inductor, such as Figures 1 to 6 As shown, a preferred embodiment of the integrally molded multi-group dual-coil TLVR inductor of this utility model includes: a first magnetic core 1 and a second magnetic core 2 arranged opposite to each other, at least one third magnetic core 2 arranged between the first magnetic core 1 and the second magnetic core 2, and a coupled dual-coil structure arranged between the first magnetic core 1, the second magnetic core 2 and the third magnetic core 2 respectively.

[0026] This embodiment, by setting at least one third magnetic core 2 between the first magnetic core 1 and the second magnetic core 2, and by setting a coupled dual-coil structure between the first magnetic core 1 and the third magnetic core 2, and between the second magnetic core 2 and the third magnetic core 2, can effectively improve space utilization and integration compared to the prior art.

[0027] Furthermore, in this embodiment, the dual-coil structure includes a primary coil 3 and a secondary coil 4. A positioning block 5 for positioning the secondary coil 4 is provided in the middle of the first magnetic core 1 and the second magnetic core 2, and in the middle of the front and back sides of the third magnetic core 2. A positioning groove is formed around the positioning block 5 in the middle part of the first magnetic core 1 and the second magnetic core 2, and in the middle position of the front and back sides of the third magnetic core 2. The primary coil 3 and the secondary coil 4 are disposed in the positioning groove. The surface of the secondary coil 4 is provided with an insulating coating. The secondary coil 4 is attached to the primary coil 3.

[0028] In this embodiment, the size of the primary coil 3 is slightly larger than the size of the secondary coil 4.

[0029] During assembly, the secondary coil 4 wraps around the positioning block 5, the positioning groove wraps around the primary coil 3, and the secondary coil 4 is fitted to the primary coil 3. This not only limits the position of the primary coil 3 and the secondary coil 4 to prevent them from moving, but also effectively reduces the overall volume of the inductor.

[0030] As one implementation scheme, in this embodiment, the first magnetic core 1 and the second magnetic core 2 have the same structure, and both the front and back sides of the first magnetic core 1, the second magnetic core 2, and the third magnetic core 2 are E-shaped structures, and the positioning groove is U-shaped.

[0031] Furthermore, in this embodiment, the primary coil 3 is U-shaped, and the two free ends of the primary coil 3 extend outward to form the first pin 7 and the second pin 8.

[0032] The secondary coil 4 is U-shaped, and the two free ends of the secondary coil 4 extend inward to form the third pin 9 and the fourth pin 10. The first pin 7, the second pin 8, the third pin 9 and the fourth pin 10 are flush.

[0033] In this embodiment, the two free ends of the primary coil 3 are extended outward to form the first pin 7 and the second pin 8, while the two free ends of the secondary coil 4 are extended inward to form the third pin 9 and the fourth pin 10. The first pin 7, the second pin 8, the third pin 9 and the fourth pin 10 are arranged flush, which can effectively prevent short circuit current from occurring at the pins.

[0034] Furthermore, in this embodiment, the materials of the first magnetic core 1, the second magnetic core 2, and the third magnetic core 2 are iron-nickel alloys or mixed alloys with iron and nickel as the main components.

[0035] Compared to Mn-Zn ferrite materials, iron-nickel alloy materials have higher magnetic saturation characteristics, which can reduce product size by about 20% and reduce power loss by about 20%.

[0036] In preparing the integrally molded multi-coil TLVR inductor of this utility model, firstly, iron-nickel alloy material or a mixed alloy with iron-nickel as the main body is used to form the first magnetic core 1, the second magnetic core 2 and the third magnetic core 2, which are then assembled with the coupled dual coils. Then, the inductor is formed again in a mold using high temperature and high pressure to form a complete, gapless integrally molded multi-coil TLVR inductor with a coupling coefficient of over 0.97.

[0037] In summary, the beneficial effects of this utility model of an integrally molded multi-group dual-coil TLVR inductor are:

[0038] This utility model, through the above-described technical solution, includes a first magnetic core 1 and a second magnetic core 2 arranged opposite to each other, with at least one third magnetic core 2 disposed between the first magnetic core 1 and the second magnetic core 2. A coupled dual-coil structure is respectively disposed between the first magnetic core 1, the second magnetic core 2, and the third magnetic core 2, which can effectively improve the space utilization and integration level of the TLVR inductor. Furthermore, through a hot-pressing molding process, this utility model ensures that the primary coil 3 and the secondary coil 4 are tightly fitted with the first magnetic core 1, the second magnetic core 2, and the third magnetic core 2 without gaps, effectively reducing the inductor volume, lowering power loss, and improving magnetic saturation. Specifically, the product size is reduced by approximately 20%, and the product's power loss can also be reduced by approximately 20%.

[0039] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent structural transformations made under the concept of the present utility model and using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included in the patent protection scope of the present utility model.

Claims

1. An integrally formed multi-set dual coil TLVR inductor, characterized by, The first magnetic core and the second magnetic core are oppositely arranged, and at least one third magnetic core is arranged between the first magnetic core and the second magnetic core, and a coupling double-coil structure is arranged between the first magnetic core, the second magnetic core and the third magnetic core.

2. The one-piece multi-set dual-coil TLVR inductor of claim 1, wherein, The double-coil structure comprises a primary coil and a secondary coil, and a positioning block for positioning the secondary coil is arranged in the middle of the first magnetic core, the second magnetic core and the front and back surfaces of the third magnetic core, and a positioning groove is arranged around the positioning block in the middle of the first magnetic core and the second magnetic core and the middle of the front and back surfaces of the third magnetic core, the primary coil and the secondary coil are arranged in the positioning groove, the surface of the secondary coil is provided with an insulating coating, and the secondary coil is arranged in the primary coil.

3. The one-piece multi-set dual-coil TLVR inductor of claim 2, wherein, The first magnetic core, the second magnetic core and the third magnetic core are all E-shaped structures, and the positioning groove is U-shaped.

4. The one-piece multi-set dual-coil TLVR inductor of claim 2, wherein, The primary coil is U-shaped, and the two free ends of the primary coil extend outward to form a first pin and a second pin.

5. The one-piece multi-set dual-coil TLVR inductor of claim 4, wherein, The secondary coil is U-shaped, and the two free ends of the secondary coil extend inward to form a third pin and a fourth pin, and the first pin, the second pin, the third pin and the fourth pin are flush.

6. The one-piece multi-set dual-coil TLVR inductor of claim 1, wherein, The material of the first magnetic core, the second magnetic core and the third magnetic core is iron-nickel alloy or a mixed alloy with iron-nickel as the main body.

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