A co-secondary combined four-phase ring TLVR inductor

Abstract

This invention discloses a common-secondary combined four-phase toroidal TLVR inductor, assembled from prefabricated pairs of primary magnetic cores, secondary magnetic cores, a single secondary coil, and four primary coils. The secondary magnetic core has two T-shaped second slots formed by a central strip-shaped rib and four corner bosses. The secondary coils are located within these T-shaped second slots and are open-looped around the strip-shaped rib. Every two primary coils are joined together within one T-shaped second slot, with a portion of their middle sections parallel and abutting the secondary coils. The primary magnetic core covers both coils and is flush with the edges of the secondary magnetic core, forming a single, integrally solidified unit. A set of secondary electrode pads is formed on the bottom of one side of the package for the secondary coils, and four sets of primary electrode pads are formed on the top of each side of the package and the bottom of its adjacent right side for the primary coils. This inductor helps reduce space requirements and improves the transient response of inductors. The coupling coefficient between any two phases of the TLVR is less than 0.1, further improving the circuit's operating environment.

Description

Technical Field

[0001] This utility model relates to an inductor device, and more particularly to a common-secondary combined four-phase ring 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 an emerging VR (Voltage Regulator) power supply architecture. Its biggest difference from the traditional DC to DC Buck and DC (DC) architectures is that it improves the traditional single-wound ordinary inductor into a TLVR inductor with dual windings, 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 structural form.

[0004] Currently, when designing TLVR inductors, in addition to the primary goal of improving coupling efficiency between the two coil stages, the number of components and the space occupied in high-density PCBs are also key concerns. Therefore, the integration of multiple TLVR inductors within limited space and the optimization of coupling coefficients have 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 common secondary combined four-phase ring TLVR inductor, which optimizes the internal structure of the device to reduce the space occupied by multi-phase integrated devices and improve the performance of the finished product.

[0006] One technical solution of this utility model to achieve the above-mentioned objective is: a common-secondary combined four-phase toroidal TLVR inductor, which is assembled from prefabricated pairs of primary magnetic cores, secondary magnetic cores, a single secondary coil, and four primary coils. The secondary magnetic core is provided with two T-shaped second slots formed by a central strip-shaped rib and four corner bosses. The secondary coil is located in the T-shaped second slot and is open-loop surrounding the strip-shaped rib. Every two primary coils are spliced ​​and located in one T-shaped second slot, with a portion of their middle sections parallel and close to the secondary coil. The primary magnetic core covers the two coils and is spliced ​​and heat-pressed with the secondary magnetic core to form a whole. The secondary coil has a set of secondary electrode pads formed on the bottom of one side of the package. The primary coil has four sets of primary electrode pads formed on the top of each side of the package and the bottom of the adjacent right side.

[0007] Furthermore, the primary magnetic core is provided with two T-shaped first receiving slots formed by a central strip-shaped rib and four corner bosses. The two T-shaped first receiving slots are connected to each other on the first sidewall of the primary magnetic core near the flat bottom edge of the strip-shaped rib. On the second and fourth sidewalls of the primary magnetic core opposite to the strip-shaped rib, a first type of notch is formed to allow partial accommodation of the primary coil. One of the T-shaped first receiving slots extends to the third sidewall of the primary magnetic core to form a second type of notch for partial accommodation of the primary coil and one end of the secondary coil. The other T-shaped first receiving slot extends to the third sidewall of the primary magnetic core to form a third type of notch for accommodation of the other end of the secondary coil, and extends to the first sidewall of the primary magnetic core to form a first type of notch for partial accommodation of the primary coil.

[0008] Furthermore, the two T-shaped second slots are connected at the fifth sidewall of the secondary magnetic core near the flat bottom edge of the strip-shaped rib. The sixth and eighth sidewalls of the secondary magnetic core on both sides opposite the strip-shaped rib each form a first-type notch for partial accommodation of the primary coil. One of the T-shaped second slots extends at the seventh sidewall of the secondary magnetic core to form a first-type notch for partial accommodation of the primary coil. The other T-shaped second slot forms a flared groove at the seventh sidewall of the secondary magnetic core and extends at the fifth sidewall of the secondary magnetic core to form a first-type notch for partial accommodation of the primary coil.

[0009] Furthermore, the primary coil is formed by cutting and bending a flat copper strip, including a middle section bent at a right angle in a flat state and a bent leg section bent vertically in the opposite direction, and the entire surface of the primary coil is covered with insulating varnish.

[0010] Furthermore, the secondary coil is formed by cutting and bending flat enameled wire, including a U-shaped segment that is continuously bent at right angles in a vertical state and a lead segment that is bent vertically in the same direction and corrected to be coplanar.

[0011] Furthermore, both the primary and secondary magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

[0012] Furthermore, the surface of the thermo-pressed inductor semi-finished product is provided with a roll-sprayed insulating coating, and the top and bottom surfaces of the inductor semi-finished product are subjected to paint stripping and electroplating treatment at the ends of the two-stage coils to form the electrode pads corresponding to the PCB assembly.

[0013] Another technical solution of this utility model to achieve the above-mentioned objective is: a common-secondary combined four-phase toroidal TLVR inductor, which is assembled from prefabricated pairs of primary magnetic cores, secondary magnetic cores, a single secondary coil, and four primary coils. The secondary magnetic core is provided with two T-shaped second slots formed by a central strip-shaped rib and four corner bosses. The secondary coil is located in the T-shaped second slot and surrounds the strip-shaped rib in an open loop. Every two primary coils are spliced ​​and located in one T-shaped second slot, with a part of their middle section parallel and close to the secondary coil. The primary magnetic core covers the two coils and is spliced ​​flush with the secondary magnetic core. All contact positions of the two magnetic cores and the two coils are glued and baked to cure as a whole. The secondary coil has a set of secondary electrode pads formed on the bottom of one side of the package. The primary coil has four sets of primary electrode pads formed on the top of each side of the package and the bottom of the adjacent right side.

[0014] Compared with existing technologies, the advantages of the TLVR inductor of this invention are as follows: The inductor optimizes the forming shape of the magnetic core relative to the multi-phase TLVR coils in the assembly, and the primary coil and its electrode pads are distributed in a ring-shaped polygonal pattern. This facilitates stable packaging of the assembly, improves insulation isolation between the four-phase two-stage coils, reduces the coupling coefficient between any two-phase TLVR coils to less than 0.1, and improves the transient response of this type of inductor. Therefore, it can be integrated into high-density PCBs and better applied in the manufacturing of power supply hardware for popular industries such as AI, data centers, autonomous driving, and smart scenarios. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the secondary magnetic core of the TLVR inductor of this utility model.

[0016] Figure 2 This is a three-dimensional structural diagram of the primary magnetic core of the TLVR inductor of this utility model.

[0017] Figure 3 This is a three-dimensional structural diagram of the primary coil of the TLVR inductor of this utility model.

[0018] Figure 4 This is a three-dimensional structural diagram of the secondary coil of the TLVR inductor of this utility model.

[0019] Figure 5 This is a schematic diagram of the assembly state of the two-stage coil of the TLVR inductor of this utility model.

[0020] Figure 6 This is a schematic diagram showing the evolution of the external shape of a preferred embodiment of the common-secondary combined four-phase toroidal TLVR inductor of this utility model.

[0021] Figure 7 This is a schematic diagram showing the evolution of the external shape of a preferred embodiment of the common-secondary combined four-phase toroidal TLVR inductor of this utility model. Detailed Implementation

[0022] 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 a part of this application, and not all of it. Based on the following embodiments, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this application.

[0023] To reduce the space occupied by finished inductors on high-density PCBs, efforts are focused on optimizing the internal structure of the magnetic core and the coil forming structure to achieve integrated multi-inductor design. Key innovative features include... Figures 1 to 6 As shown, a preferred embodiment of the common-secondary combined four-phase toroidal TLVR inductor is assembled from prefabricated pairs of primary magnetic cores 2, secondary magnetic cores 1, a single secondary coil 4, and four primary coils 3. The secondary magnetic core 1 is integrally formed as a cube, with a flat bottom surface and two T-shaped second slots on its top surface formed by a central strip-shaped rib 11 and four corner bosses. The secondary coil 4 is located in the two T-shaped second slots and surrounds the central strip-shaped rib 11 in an open loop. Every two primary coils 3 are joined together in one T-shaped second slot, with a portion of their middle section parallel and adjacent to a portion of the secondary coil. The primary magnetic core 2 covers both coils and is flush with the secondary magnetic core 1, then thermo-pressed into a single unit. As the connection base for the inductor facing the PCB, the secondary coil has a set of secondary electrode pads 62 formed at the bottom of one side of the package, and the primary coil has a set of primary electrode pads 61 formed at the top of each side of the package and the bottom of its adjacent right side.

[0024] As can be seen from the inductor structure outlined above, for the pre-assembled unit, each group of primary and secondary coils is isolated by the strip-shaped ribs of the secondary magnetic core. The two primary coils on each side of the strip-shaped ribs are further segmented from the secondary coils, and each group of primary and secondary coils is also mutually insulated. For the assembled unit, the first and second T-shaped slots enclose the four groups of coils, while the strip-shaped ribs and corner bosses outside the slots are completely closed. This results in four-phase primary and secondary coils that achieve reliable isolation while being integrated as a single device, thereby minimizing mutual coupling interference, achieving a coupling coefficient k < 0.1, and increasing the coupling coefficient of each phase's primary and secondary coils.

[0025] Looking at more detailed features, such as Figure 2 The primary magnetic core 2 shown above has two T-shaped first receiving slots formed by the strip-shaped rib 21 in the middle of the primary core and the four corner bosses. The two T-shaped first receiving slots are connected to each other on the first side wall of the primary magnetic core near the flat bottom edge of the strip-shaped rib (lower right corner of the figure). On the second side wall (right side of the figure) and the fourth side wall (left side of the figure) on both sides of the primary magnetic core opposite to the strip-shaped rib, a first type of notch 23a is formed to accommodate a part of the primary coil. One of the right-side T-shaped first receiving slots 22b extends to the third side wall of the primary magnetic core (middle of the top side of the figure) to form a second type of notch 23b to accommodate a part of the primary coil and one end of the secondary coil side by side. The other left-side T-shaped first receiving slot 22a extends to the third side wall of the primary magnetic core to form a third type of notch 22c to accommodate the other end of the secondary coil, and extends to the first side wall of the primary magnetic core to form a first type of notch to accommodate a part of the primary coil.

[0026] like Figure 1 The secondary magnetic core 1 shown above has two T-shaped second slots connected at the fifth sidewall (upper right side of the diagram) near the flat bottom edge of the strip-shaped rib. A single notch 13 is formed on each of the sixth (upper left corner of the diagram) and eighth (lower right side of the diagram) sidewalls opposite the strip-shaped rib, allowing partial accommodation of the primary coil. One of the left-side T-shaped second slots 12a extends at the seventh sidewall (lower left corner of the diagram) to form a single notch 13 for partial accommodation of the primary coil, while the other right-side T-shaped second slot 12b forms a flared groove on the seventh sidewall and extends at the fifth sidewall to form a single notch for partial accommodation of the primary coil. Here, all single notches are shaped like the aforementioned first type of notch; the dimensions of each type of notch match the dimensions and shapes of the assembled two-stage coils.

[0027] More specifically, such as Figure 3The primary coil 3 shown above is formed by cutting and bending a flat copper strip, including a primary middle section 31 bent at a right angle in a flat state and a bent leg section bent vertically in the opposite direction, including a primary upper end 32 and a primary lower end 33, and the entire surface of the primary coil is covered with insulating varnish to enhance insulation and isolation from the secondary coil. And as... Figure 4 The secondary coil 4 shown above is formed by cutting and bending flat enameled wire, including a U-shaped segment 41 with continuous right-angle bends in an upright state and a lead segment 42 with bends in the same direction and coplanar correction. This fits into an open-loop wrapping of the strip-shaped rib 11 in the middle of the secondary winding. In the packaged state, the insulation isolation between the two coils is maintained above DC 150V, while still ensuring a high intra-group coupling coefficient.

[0028] After the semi-finished product formed by the above-mentioned thermo-press packaging is discharged, it still needs to undergo surface painting treatment to form an insulating coating 5 on its surface. Then, the paint is partially peeled off and electroplated on the corresponding primary coil and secondary coil to form electrode pads, thereby increasing the isolation distance between them to meet the application assembly requirements of circuit board soldering.

[0029] like Figure 6 The diagram shows the external shape evolution during the manufacturing process of a preferred embodiment of the TLVR inductor. The process is briefly described as follows: S1. Pre-fabrication: A first mold and a second mold are fabricated according to the preset shape and design dimensions. Magnetic core powder is then filled into both molds and molded to obtain the primary and secondary magnetic cores. Flat copper strips and flat enameled wires are used as materials, and prefabricated in batches according to specifications to obtain the secondary and primary coils. All of the above parts can be prefabricated in batches. The magnetic powder used for prefabricating the two magnetic cores is one or a mixture of two or more of Fe-based / FeSiCr / FeNi / FeSiAl / FeSi / amorphous / nanocrystalline materials, with epoxy resin, silicone resin, or acrylic resin added selectively. The cold pressing pressure is between 6 Tons / cm² and 10 Tons / cm².

[0030] S2. First, take one secondary magnetic core with the second slot of the T-shaped housing facing upwards. Then, take four primary coils and insert them one-to-one into the second slots of each T-shaped housing, abutting against the adjacent four corner bosses, to obtain the first pre-assembled body A. Next, take one secondary coil and press... Figure 5 The assembly method shown is located in the second T-shaped slot, with the inner open ring wrapping around the middle strip-shaped rib 11 of the secondary winding, and the outer side pressing the surrounding primary coils against each other to form the second pre-assembled body B. Here, the slot width of the second T-shaped slot is sufficient to fit the two coils together with a gap and to limit and prevent slippage; while the order in which the primary and secondary cores are assembled facing the secondary core can be customized and is not deliberately limited.

[0031] S3. Take a primary magnetic core and make the first slot of the T-shaped coil face down. Make the upward-curving parts of the two coils fall into the corresponding notches. After aligning the two magnetic cores, combine them from top to bottom to obtain a complete assembly C.

[0032] S4. Transfer the complete assembly into a hot-press molding die, fill all pores and seams with magnetic powder, and then apply hot-pressing pressure and temperature to the die to obtain a package D with completely eliminated seams. Here, the magnetic powder used for hot pressing is one or more of Fe-based / FeSiCr / FeNi / FeSiAl / amorphous / nanocrystalline materials, and is uniformly mixed with epoxy resin, silicone resin or acrylic resin. The packaging parameters include a molding temperature between 100-200℃, a molding pressure between 4 Tons / cm² and 12 Tons / cm², and a molding time between 30-180 seconds.

[0033] S5. Then, the package D is transferred to the roller spraying workshop for full coverage with the insulating coating 5 to obtain the full package E.

[0034] S6. Then, the paint is partially stripped from the entire casing using a laser stripping process to expose the copper material at each end of the two-stage coil. Then, electroplating is performed on each exposed copper surface to obtain four sets of primary electrode pads 61 and one set of secondary electrode pads 62, and finally, a finished product F of a common-secondary combined four-phase toroidal TLVR inductor with smooth sidewalls is obtained.

[0035] In addition, such as Figure 7 The image shows the external evolution of a preferred embodiment of the TLVR inductor during its manufacturing process. The manufacturing process and finished product appearance differ slightly from the preferred embodiment, as briefly described below: In step S1, although the components are basically the same in terms of prefabricated shape, after the secondary coil is bent and formed or the primary coil is bent and painted, the coating / paint is peeled off and electroplated at their respective ends to directly form the electrode pad 6. The magnetic core used can be a manganese zinc ferrite molded by compression molding or a mixture of alloy materials (one or more of FeSi / FeNi / FeSiAl powders) sintered at high temperature. The layered assembly shape and sequence in steps S2 to S3 are the same. The difference is that all contact positions of each component are glued and layered and pressed together. That is, glue is first applied in sections in the second T-shaped cavity and one secondary coil and four primary coils are installed without any order. Then, glue is applied in a dispersed manner on the surface of the two coils facing upwards and the surface of the secondary magnetic core (including the strip-shaped ribs and four corner bosses in the middle of the secondary coil). Finally, the primary magnetic core is combined with it to form a complete assembly G, which is then cured and shaped by a baking process. Unlike the finished product of the preferred embodiment, the resulting inductor is in a more primitive state on all four sides, with no magnetic powder filling the gaps and seams; however, the surface insulation performance and the insulation isolation between coils remain reliable.

[0036] In summary, the above introduction and detailed description of the common-secondary combined four-phase toroidal TLVR inductor of this utility model demonstrate that, compared with the prior art, this solution possesses substantial features and advancements. Its technical effects are as follows: This inductor optimizes the forming shape of the magnetic core relative to the multi-phase TLVR coils in its assembly, and the primary coil and its electrode pads are distributed in a ring-shaped polygonal pattern. This facilitates stable encapsulation of the assembly, improves insulation isolation between the four-phase two-stage coils, reduces the coupling coefficient between any two-phase TLVR coils to less than 0.1, and improves the transient response of this type of inductor. Therefore, it can be integrated into high-density PCBs and better applied in the manufacturing of power supply hardware for popular industries such as AI, data centers, autonomous driving, and smart scenarios.

[0037] 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 common-secondary combined four-phase toroidal TLVR inductor, characterized in that: The inductor is assembled from prefabricated pairs of primary magnetic cores, secondary magnetic cores, a single secondary coil, and four primary coils. The secondary magnetic core has two T-shaped second slots formed by a central strip-shaped rib and four corner bosses. The secondary coil is located in the T-shaped second slot and surrounds the strip-shaped rib in an open loop. Every two primary coils are spliced ​​together and located in one T-shaped second slot, with a portion of their middle sections parallel and close to the secondary coil. The primary magnetic core covers the two coils and is spliced ​​with the secondary magnetic core along the edge and thermo-pressed into a single unit. The secondary coil has a set of secondary electrode pads formed on the bottom of one side of the package, and the primary coil has four sets of primary electrode pads formed on the top of each side of the package and the bottom of the adjacent right side.

2. The common-secondary combined four-phase toroidal TLVR inductor according to claim 1, characterized in that: The primary magnetic core is provided with two T-shaped first receiving slots formed by a central strip-shaped rib and four corner bosses. The two T-shaped first receiving slots are connected to each other on the first sidewall of the primary magnetic core near the flat bottom edge of the strip-shaped rib. On the second and fourth sidewalls of the primary magnetic core opposite to the strip-shaped rib, a first type of notch is formed to accommodate a portion of the primary coil. One of the T-shaped first receiving slots extends to the third sidewall of the primary magnetic core to form a second type of notch to accommodate a portion of the primary coil and one end of the secondary coil side by side. The other T-shaped first receiving slot extends to the third sidewall of the primary magnetic core to form a third type of notch to accommodate the other end of the secondary coil, and extends to the first sidewall of the primary magnetic core to form a first type of notch to accommodate a portion of the primary coil.

3. The common-secondary combined four-phase toroidal TLVR inductor according to claim 1, characterized in that: Two T-shaped second slots are connected at the fifth sidewall of the secondary magnetic core near the flat bottom edge of the strip-shaped rib. On the sixth and eighth sidewalls of the secondary magnetic core opposite to the strip-shaped rib, a first-type notch is formed to allow partial accommodation of the primary coil. One of the T-shaped second slots extends at the seventh sidewall of the secondary magnetic core to form a first-type notch to allow partial accommodation of the primary coil. The other T-shaped second slot forms a flared groove at the seventh sidewall of the secondary magnetic core and extends at the fifth sidewall of the secondary magnetic core to form a first-type notch to allow partial accommodation of the primary coil.

4. The co-secondary combined quadrature loop TLVR inductor of claim 1, wherein: The primary coil is formed by cutting and bending a flat copper strip, including a middle section that is bent at a right angle in a flat state and a bent leg section that is bent vertically in the opposite direction, and the entire surface of the primary coil is covered with insulating varnish.

5. The common-secondary combined four-phase toroidal TLVR inductor according to claim 1, characterized in that: The secondary coil is formed by cutting and bending flat enameled wire, including a U-shaped segment with continuous right-angle bends in a vertical position and a lead segment that is bent vertically in the same direction and corrected to be coplanar.

6. The co-secondary combined four-phase ring TLVR inductor of claim 1, wherein: Both the primary and secondary magnetic cores are cold-pressed bodies made of powder material based on a customized mold.

7. The co-secondary combined quadrature loop TLVR inductor of claim 1, wherein: The surface of the thermo-pressed inductor semi-finished product is coated with a roll-sprayed insulating coating, and the top and bottom surfaces of the inductor semi-finished product are treated with paint stripping and electroplating at the ends of the two-stage coils to form the electrode pads corresponding to the PCB assembly.

8. A co-subcombination four-phase ring TLVR inductor characterized by: The inductor is assembled from prefabricated pairs of primary magnetic cores, secondary magnetic cores, a single secondary coil, and four primary coils. The secondary magnetic core has two T-shaped second slots formed by a central strip-shaped rib and four corner bosses. The secondary coil is located in the T-shaped second slot and surrounds the strip-shaped rib in an open loop. Every two primary coils are spliced ​​together in one T-shaped second slot, with a portion of their middle sections parallel and close to the secondary coil. The primary magnetic core covers the two coils and is flush with the edge of the secondary magnetic core. All contact points of the two magnetic cores and the two coils are glued and baked into a single unit. The secondary coil has a set of secondary electrode pads formed on the bottom of one side of the package, and the primary coil has four sets of primary electrode pads formed on the top of each side of the package and the bottom of the adjacent right side.

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