A thermally compressed coupled tlvr inductor

Abstract

This invention discloses a TLVR inductor with improved thermo-pressure coupling. It is assembled from a pre-fabricated concave U-shaped magnetic core, an I-plate magnetic core, and a primary coil and a secondary coil. One side of the concave U-shaped magnetic core is flat, while the other side has a U-shaped groove surrounding a central protrusion. The primary coil is continuously bent into a U-shape in side view and installed in the U-shaped groove, forming the primary inductor. The secondary coil is installed in the concave U-shaped magnetic core, partially surrounding and partially covering the protrusion. The ends of the two coils are arranged side-by-side with the primary coil on the outside and the secondary coil on the inside. The I-plate magnetic core covers both coils and is assembled flush with the concave U-shaped magnetic core. The thermo-pressed package has four electrode pads formed on one side. This inductor helps reduce space occupation and interference to the surrounding environment, significantly improving the coupling efficiency of inductor devices, and is suitable for high-density, fast-response power module systems.

Description

Technical Field

[0001] This utility model relates to an inductor device, and more particularly to a TLVR inductor for improving thermo-pressure coupling in a TLVR architecture, 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] As edge devices such as AI servers and high-speed computing units increasingly demand higher power supply stability and dynamic response speed, traditional multiphase power supplies face challenges in terms of space constraints and functional density. To address switching losses and output filter size issues under high-frequency loads, the industry is gradually adopting the TLVR architecture, which utilizes coupled inductors to connect phases in series to improve instantaneous response.

[0004] However, the inductors in existing multiphase TLVR architecture circuits are mostly designed by assembling the primary coil, secondary coil and magnetic core into a single phase. This has problems such as unstable coupling coefficient and the need to occupy a large design space. It is necessary to propose targeted structural optimization or molding process improvement. Summary of the Invention

[0005] The purpose of this invention is to propose a TLVR inductor with improved thermo-pressure coupling, aiming to enhance the performance of inductor devices and optimize space utilization.

[0006] The technical solution of this utility model to achieve the above-mentioned objective is: a TLVR inductor with improved thermo-pressure coupling, which is assembled from a pre-fabricated concave U-shaped magnetic core, an I-shaped magnetic core, and a primary coil and a secondary coil. One side of the concave U-shaped magnetic core is flat, and the other side is provided with a U-shaped groove surrounding the central protrusion. The primary coil is continuously bent into a U-shape in side view and installed in the U-shaped groove to form a primary inductor. The secondary coil is installed in the concave U-shaped magnetic core, partially surrounding and partially covering the protrusion. The ends of the two coils are arranged side by side with the primary coil on the outside and the secondary coil on the inside. The I-shaped magnetic core covers the two coils and is assembled flush with the concave U-shaped magnetic core. The thermo-pressed package is formed into four electrode pads on one side.

[0007] Furthermore, the concave U-shaped magnetic core is integrally formed into a cube, wherein the top of the protrusion is flush with the top surface of the concave U-shaped magnetic core, and the sides and bottom of the protrusion are separated from the annular wall of the concave U-shaped magnetic core by the thickness of a primary coil, and the depth of the U-shaped groove is greater than the width of the primary coil and the thickness of the secondary coil.

[0008] Furthermore, both the concave U-shaped magnetic core and the I-piece magnetic core are cold-pressed bodies made of powder material based on a customized mold.

[0009] Furthermore, the primary coil is formed by bending a copper strip, and the ends of the primary coil are bent in opposite directions and overlapped in the notches on both sides of the top of the U-shaped groove.

[0010] Furthermore, the secondary coil is formed by stamping and bending copper sheets, and the secondary coil has the same side view shape as the primary coil; the top of the secondary coil is gathered and bent towards the depth of the U-shaped groove.

[0011] Furthermore, the hot-pressed package is formed into a flat surface on the exposed side of the two-stage coil.

[0012] 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.

[0013] Compared with existing technologies, the advantages of this inductor are reflected in the following aspects: by optimizing the molding and assembly structure of the magnetic core and the two-stage coils, it helps to reduce the space occupied by the inductor in high-density PCBs and its interference to the surrounding environment. On the other hand, it improves the creepage distance between the coil contacts and the coupling coefficient between the two-stage inductors. This further improves the circuit's operating environment and promotes the development of hardware performance in application scenarios such as servers, data centers, and autonomous driving. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural diagram of the concave U-shaped magnetic core in the TLVR inductor of this utility model.

[0015] Figure 2 This is a three-dimensional structural diagram of the magnetic core in the TLVR inductor of this utility model.

[0016] Figure 3 This is a schematic diagram of the primary magnetic core in the TLVR inductor of this utility model.

[0017] Figure 4 This is a schematic diagram of the secondary magnetic core in the TLVR inductor of this utility model.

[0018] Figure 5 This is a schematic diagram illustrating the state evolution during the manufacturing process of the TLVR inductor of this utility model. Detailed Implementation

[0019] 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.

[0020] This invention proposes a TLVR inductor for improving thermo-pressure coupling, such as... Figures 1 to 5 As shown, the basic structure of a preferred embodiment of the TLVR inductor is assembled from a prefabricated concave U-shaped magnetic core 1, an I-shaped magnetic core 2, and a primary coil 3 and a secondary coil 4. The structure of each component is summarized as follows: one side of the concave U-shaped magnetic core 1 is flat, and the other side has a U-shaped groove 11 surrounding the central protrusion 12; the primary coil 3 is continuously bent into a U-shape in side view and installed in the U-shaped groove 11 to form the primary inductor; the secondary coil 4 is also installed in the U-shaped groove of the concave U-shaped magnetic core, with part of it surrounding the protrusion and part of it covering the protrusion. The ends of the two coils are arranged side-by-side with the primary coil on the outside and the secondary coil on the inside. The I-shaped magnetic core 2 covers the two coils and is assembled flush with the concave U-shaped magnetic core. The thermo-pressed package has four electrode pads formed on one side.

[0021] The aforementioned magnetic cores and coils can be prefabricated and reused in batches. Based on the overview of the technical solution and the illustrations of preferred embodiments, the detailed features of each functional component of this TLVR inductor also include: Figure 1 As shown, the concave U-shaped magnetic core is integrally formed into a cube, wherein the top of the protrusion is flush with the top surface of the concave U-shaped magnetic core (the actual assembly and finished product state is the bottom or bottom surface), the two sides and the bottom of the protrusion are separated from the annular wall of the concave U-shaped magnetic core by the thickness of a primary coil 3, and the depth of the U-shaped groove 11 is greater than the width of the primary coil 3 and the thickness of the secondary coil 4. Figure 2 The magnetic core shown is of a standard design and mainly functions as a side cover, so further details are omitted.

[0022] like Figure 3 As shown, the primary coil 3 is formed by bending a copper strip, and the ends 32 of the primary coil are bent in opposite directions and overlapped in the notches on both sides of the top of the U-shaped groove. Figure 4As shown, the secondary coil 4 is formed by stamping and bending a copper sheet, and the main body 41 of the secondary coil has the same side view shape as the main body 31 of the primary coil and basically overlaps with it. Unlike the open bending at the end of the primary coil, the secondary coil is bent at the top and the free end 42 is bent towards the depth of the U-shaped groove. The outer edge distance b of the free end 42 is smaller than the inner edge distance a of the end 32. Both coils are surface-insulated after processing. Thus, from the side view of the inductor, the two coils are mutually insulated and side by side, while the ends and free ends used for external circuits are side by side on the same side of the inductor and separated from each other. It should be noted that the width of the primary coil refers to the distance between the left and right sides of the coil shown in the figure, and the thickness of the primary coil refers to the distance between the outer and inner surfaces of its extensions and bends. The secondary coil itself is a copper sheet, so its thickness is the distance between the top and bottom surfaces in the flattened state.

[0023] Both of the aforementioned magnetic core shapes are prefabricated assemblies based on powder materials and custom molds. The mass production of both utilizes a cold-pressing process. The powder used for the magnetic core can be one or more mixtures of Fe-based / FeSiCr / FeSiAl / FeNi / FeSi / amorphous / nanocrystalline materials, with one of epoxy resin, silicone resin, or acrylic resin added and stirred evenly before being injected into a custom mold conforming to the device's shape. The molding pressure range is 6-12 Tons / cm².

[0024] To improve the overall compactness and structural stability of the device, the assembled components need to be thermo-pressed into a package, and then undergo a series of post-processing steps such as roller spraying of insulating varnish, partial varnish stripping, and electroplating before being tested and discharged. Therefore, in order to make the parts of the two-stage coil used to form the electrode pads integrally molded, thermo-pressing encapsulation molds and thermo-pressing processes are used to make the exposed sides of the two-stage coils into a flat surface.

[0025] like Figure 5As shown in the schematic diagram of the complete manufacturing process of the preferred embodiment of the TLVR inductor: First, two types of magnetic cores and two-stage coils are prefabricated. Then, the first assembly is performed, in which the primary coil 3 is inserted into the U-shaped groove 11 of the concave U-shaped magnetic core 1 to obtain the primary inductor A. Then, the second assembly is performed, in which the secondary coil is placed against the side of the primary magnetic core and its free end is inserted between the two ends of the primary coil to obtain the primary and secondary inductor semi-finished products B. Then, the final assembly is performed, in which the I-piece magnetic core is aligned with the concave U-shaped magnetic core to obtain the complete assembly C. Then, it is transferred to the corresponding mold for hot pressing and packaging. All gaps between the inner wall of the hot pressing mold and the complete assembly are filled with one or more of the following: Fe-based / FeNi / FeSiAl / amorphous or nanocrystalline. Then, it is held at a molding temperature range of 100-200℃ and a molding pressure of 4-12 Tons / cm² for 30-180 seconds to obtain the hot-pressed package D. After cooling, the package is painted to fully cover its surface with an insulating enamel film 5, resulting in an enamel-coated body E. Then, partial enamel stripping is performed to expose both the free-end copper surface 43 and the end copper surface 33, resulting in an electroplating pre-body F. Finally, electroplating is used to form the four electrode pads 6 spaced side-by-side on the bottom surface of the TLVR inductor. The finished inductor devices undergo external inspection, testing, quality inspection, packaging, and shipment sequentially.

[0026] In summary, the preferred embodiment of the TLVR inductor with improved thermo-pressure coupling described above demonstrates that, compared to existing technologies, its technical advantages are as follows: By optimizing the molding and assembly structure of the magnetic core and the two-stage coils, it helps reduce the space occupied by the inductor in high-density PCBs and its interference to the surrounding environment. Furthermore, it improves the creepage distance between the coil contacts and the coupling coefficient between the two inductors. This further enhances the circuit's operating environment and promotes hardware performance development in application scenarios such as servers, data centers, and autonomous driving.

[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. A TLVR inductor for improving thermo-pressure coupling, characterized in that: The inductor is assembled from a prefabricated concave U-shaped magnetic core, an I-shaped magnetic core, and a primary coil and a secondary coil. One side of the concave U-shaped magnetic core is flat, and the other side has a U-shaped groove surrounding the central protrusion. The primary coil is continuously bent into a U-shape in side view and installed in the U-shaped groove to form the primary inductor. The secondary coil is installed in the concave U-shaped magnetic core, partially surrounding and partially covering the protrusion. The ends of the two coils are arranged side by side with the primary coil on the outside and the secondary coil on the inside. The I-shaped magnetic core covers the two coils and is assembled flush with the concave U-shaped magnetic core. The thermo-pressed package has four electrode pads formed on one side.

2. The TLVR inductor with improved thermo-pressure coupling according to claim 1, characterized in that: The concave U-shaped magnetic core is integrally formed into a cube, wherein the top of the protrusion is flush with the top surface of the concave U-shaped magnetic core, and the sides and bottom of the protrusion are separated from the annular wall of the concave U-shaped magnetic core by the thickness of a primary coil, and the depth of the U-shaped groove is greater than the width of the primary coil and the thickness of the secondary coil.

3. The TLVR inductor with improved thermo-pressure coupling according to claim 1, characterized in that: Both the concave U-shaped magnetic core and the I-piece magnetic core are cold-pressed bodies made of powder material based on a customized mold.

4. The TLVR inductor with improved thermo-pressure coupling according to claim 1, characterized in that: The primary coil is formed by bending copper strips, and the ends of the primary coil are bent in opposite directions and overlapped in the gaps on both sides of the top of the U-shaped groove.

5. The TLVR inductor with improved thermo-pressure coupling according to claim 1, characterized in that: The secondary coil is formed by stamping and bending copper sheets, and the secondary coil has the same side view shape as the primary coil; the top of the secondary coil is gathered and bent towards the depth of the U-shaped groove.

6. The TLVR inductor with improved thermo-pressure coupling according to claim 1, characterized in that: The hot-pressed package is formed into a flat surface on the exposed side of the two-stage coil.

7. The TLVR inductor with improved thermo-pressure coupling according to claim 1 or 6, 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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