TWI844497B - Magnetic element - Google Patents

Abstract

A magnetic element includes a first magnetic core, a second magnetic core and a coil set. The first magnetic core includes a first flank post, a second flank post and a first side post. The first side post has a first joint surface. The first flank post and the second flank post are disposed on the first joint surface, and the first flank post, the second flank post and the first side pillar form an accommodation space. The first flank post and the second flank post have a second joint surface and a third joint surface, respectively, in a face-to-face configuration. The second magnetic core is disposed in the accommodation space. The second magnetic core includes a second side post, a first end post and a second end post. The first end post and the second end post are disposed at two ends of the second side post, respectively. A first air gap, a second air gap, a third air gap and a fourth air gap are formed between the first end post and the second joint surface, between the second end post and the third joint surface, between the first end post and the first joint surface, and between the second end post and the first joint surface, respectively. The coil set surrounds the second side post.

Description

Magnetic components

The present invention relates to a magnetic element, and in particular to a magnetic element capable of adjusting efficiency according to design requirements.

Magnetic components, such as transformers and inductors, are often used in various power supplies and other devices. How to provide a magnetic component that can adjust efficiency according to design requirements is the goal pursued by people in related technical fields.

The present invention relates to a magnetic element, wherein a plurality of air gaps are formed between two magnetic cores, and the efficiency of the magnetic element can be adjusted according to design requirements by using the plurality of air gaps.

According to one aspect of the present invention, a magnetic element is provided. The magnetic element includes a first magnetic core, a second magnetic core and a coil group. The first magnetic core includes a first side column, a second side column and a first side column. The first side column has a first joint surface. The first side column and the second side column are arranged on the first joint surface of the first side column, and the first side column, the second side column and the first side column form a receiving space. The first side column and the second side column have a second joint surface and a third joint surface, respectively, and the second joint surface and the third joint surface are arranged face to face. The second magnetic core is located in the receiving space. The second magnetic core includes a second side column, a first end column and a second end column. The first end column and the second end column are respectively arranged at two ends of the second side column. There is a first air gap between the first end column and the second joint surface. There is a second air gap between the second end column and the third joint surface. There is a third air gap between the first end column and the first joint surface. There is a fourth air gap between the second end column and the first joint surface. The coil assembly goes around the second side post.

In order to better understand the above and other aspects of the present invention, the following embodiments are specifically described in detail with reference to the accompanying drawings:

The magnetic element of the present invention comprises a first magnetic core, a second magnetic core and a coil set, and a plurality of air gaps are formed between the first magnetic core and the second magnetic core. The efficiency of the magnetic element can be adjusted according to design requirements by using the plurality of air gaps.

The following will describe in detail various embodiments of the present invention, together with the accompanying drawings as examples. In addition to these detailed descriptions, the present invention can also be widely implemented in other embodiments, and any easy replacement, modification, and equivalent changes of the embodiments are included in the scope of the present invention and are subject to the subsequent patent scope. In the description of the specification, in order to enable the reader to have a more complete understanding of the present invention, many specific details and implementation examples are provided; however, these specific details and implementation examples should not be regarded as limitations of the present invention. In addition, well-known steps or components are not described in the details to avoid unnecessary limitations of the present invention. In the drawings, the same or similar element symbols are used to represent the same or similar elements.

FIG. 1 shows an assembly diagram of a magnetic element 100 according to an embodiment of the present invention; FIG. 2 shows an exploded diagram of the magnetic element 100 of FIG. 1 .

Referring to FIG. 1 and FIG. 2, the magnetic element 100 includes a first magnetic core 110, a second magnetic core 120, and a coil assembly 130. The first magnetic core 110 may include a first side post 111, a first side post 112, and a second side post 113. The first side post 111, the first side post 112, and the second side post 113 may be formed in one piece. The first side post 111, the first side post 112, and the second side post 113 may form a receiving space S. The second magnetic core 120 may include a second side post 121, a first end post 122, and a second end post 123. The second side post 121, the first end post 122, and the second end post 123 may be formed in one piece. The coil assembly 130 surrounds the second side post 121 of the second magnetic core 120. The second magnetic core 120 and the coil assembly 130 surrounding the second side column 121 may be disposed along the positive direction of the X-axis in the accommodation space S. When current flows through the coil assembly 130, the second magnetic core 120 and the first magnetic core 110 may form a closed magnetic circuit.

Figure 3A is a schematic diagram of the first magnetic core 110 of the magnetic element 100 in Figure 1; Figure 3B is a schematic diagram of the first magnetic core 110 in Figure 3A from another perspective; Figure 4A is a schematic diagram of the second magnetic core 120 of the magnetic element 100 in Figure 1; Figure 4B is a schematic diagram of the second magnetic core 120 in Figure 4A from another perspective.

Please refer to Figures 2, 3A and 3B. The first side column 111 of the first magnetic core 110 has a first joint surface 111J, and the first joint surface 111J faces the negative direction of the X-axis. In other words, the first joint surface 111J has a first normal line N1, and the first normal line N1 is parallel to the X-axis and points to the negative direction of the X-axis. In a specific embodiment, the first side column 111 may have a groove portion 111R. The groove portion 111R may be slightly recessed inward (toward the positive direction of the X-axis) from the first joint surface 111J at a position approximately in the center of the first side column 111 along the Y-axis, so that the first side column 111 generally presents a U-shaped structure.

The first side column 112 and the second side column 113 are disposed on the first joint surface 111J of the first side column 111. In a specific embodiment, the first side column 112 and the second side column 113 may respectively include first walls 112a and 113a, second walls 112b and 113b, and connecting walls 112c and 113c. The connecting walls 112c and 113c connect the first walls 112a and 113a and the second walls 112b and 113b. The first wall 112a and the second wall 112b are disposed on opposite sides of the connecting wall 112c on the Z axis, and the first wall 112a and the second wall 112b also extend toward the negative direction of the Y axis, so that the first wall 112a, the connecting wall 112c and the second wall 112b constitute a U-shaped side column. The first wall 113a and the second wall 113b are arranged on opposite sides of the connecting wall 113c on the Z axis, and the first wall 113a and the second wall 113b also extend toward the positive direction of the Y axis, so that the first wall 113a, the connecting wall 113c and the second wall 113b constitute a U-shaped side column. The second side column 112 of the first magnetic core 110 has a second joint surface 112J, and the second side column 113 of the first magnetic core 110 has a third joint surface 113J. The second joint surface 112J faces the negative direction of the Y axis, and the third joint surface 113J faces the positive direction of the Y axis. The second joint surface 112J and the third joint surface 113J are arranged face to face. In other words, the second joint surface 112J has a second normal line N2, and the third joint surface 113J has a third normal line N3. The second normal line N2 and the third normal line N3 are parallel to the Y axis and point to the negative direction and the positive direction of the Y axis respectively. In a specific embodiment, the second joint surface 112J may be the surface of the connecting wall 112c of the first side column 112 facing the accommodating space S, and the second joint surface 112J is connected to the first joint surface 111J; the third joint surface 113J may be the surface of the connecting wall 113c of the second side column 113 facing the accommodating space S, and the third joint surface 113J is connected to the first joint surface 111J.

In a specific embodiment, the first magnetic core 110 may be a substantially U-shaped magnetic core. The first side column 111, the first side column 112 and the second side column 113 of the first magnetic core 110 may each present a U-shaped structure, and the openings of the U-shaped structure are all facing the accommodation space S.

Referring to FIG. 2, FIG. 4A and FIG. 4B, the second side post 121 of the second magnetic core 120 may present a rectangular parallelepiped structure extending along the Y axis. The first end post 122 and the second end post 123 are respectively disposed at two ends of the second side post 121, for example, disposed at two ends of the second side post 121 on the Y axis. In a specific embodiment, the second magnetic core 120 may be substantially an I-shaped magnetic core. The first end post 122 and the second end post 123 may be respectively flat plate structures, and the first end post 122 and the second end post 123 are respectively perpendicular to the second side post 121.

The first end post 122 and the second end post 123 protrude from the second side post 121 in the positive and negative directions of the Z axis and the positive direction of the X axis, respectively, and the second magnetic core 120 has a flat surface 120S on one side facing the negative direction of the X axis. Referring to FIG. 1, FIG. 2 and FIG. 4A, the coil assembly 130 has an inlet end 131 for the coil to enter and start winding, and an outlet end 132 for the coil to complete winding. The inlet end 131 of the coil assembly 130 can be set on this flat surface 120S, so that the coil enters along one side of this flat surface 120S and begins to wind around the second side post 121 of the second magnetic core 120. Since the coil starts to be wound as soon as the wire enters from one side of the flat surface 120S, when the coil is gradually wound and stacked on the second side column 121, the subsequent wound coil will not overlap or squeeze the coil of the wire inlet end 131, thereby avoiding the risk of short circuit caused by wear of the coil of the wire inlet end 131. In addition, the coil assembly 130 can be automatically wound on a winding machine in an automated manner.

On the other hand, since one side of the coil assembly 130 in the negative direction of the X-axis is exposed to the outside, the overall heat dissipation space can be increased, which helps to improve the heat dissipation efficiency.

The first magnetic core 110 and the second magnetic core 120 can be made of different materials. In one embodiment, the first magnetic core 110 can be made of a material with a larger vacuum magnetic permeability to improve the efficiency of the inductance under light load. For example, the first magnetic core 110 can be made of a manganese-zinc alloy, and the second magnetic core 120 can be made of an iron-nickel alloy.

FIG. 5 is a schematic three-dimensional cross-sectional view of the magnetic element 100 in FIG. 1 ; and FIG. 6 is a schematic cross-sectional view of the magnetic element 100 in FIG. 1 .

Please refer to Figures 5 and 6. A first air gap G1 may exist between the first end column 122 of the second magnetic core 120 and the second joint surface 112J of the first side column 112 of the first magnetic core 110; a second air gap G2 may exist between the second end column 123 of the second magnetic core 120 and the third joint surface 113J of the second side column 113 of the first magnetic core 110. The first air gap G1 and the second air gap G2 are the distances between the first end column 122 and the second joint surface 112J, and the second end column 123 and the third joint surface 113J on the Y axis, respectively. The size of the first air gap G1 and the second air gap G2 can be adjusted according to the specifications of the power supply actually used by the magnetic element 100. For example, the size of the first air gap G1 and/or the second air gap G2 can be increased to adjust the required operating current of the magnetic element 100. The sizes of the first air gap G1 and the second air gap G2 can be adjusted by changing the shapes/sizes of the first end post 122 and the second end post 123 of the second magnetic core 120 .

In addition, a third air gap G3 may exist between the first end column 122 of the second magnetic core 120 and the first joint surface 111J of the first side column 111 of the first magnetic core 110, and the third air gap G3 is connected to the first air gap G1; a fourth air gap G4 may exist between the second end column 123 of the second magnetic core 120 and the first joint surface 111J of the first side column 111 of the first magnetic core 110, and the fourth air gap G4 is connected to the second air gap G2. The third air gap G3 and the fourth air gap G4 are the distances between the first end column 122 and the first joint surface 111J, and the distances between the second end column 123 and the first joint surface 111J on the X axis, respectively. The sizes of the third air gap G3 and the fourth air gap G4 are adjustable to achieve the required inductance. For example, the size of the third air gap G3 and the fourth air gap G4 can be adjusted starting from 0, that is, the first end post 122 and the second end post 123 can be attached to the first joint surface 111J, as shown in FIG. 7, which shows a cross-sectional schematic diagram of a magnetic element 100a according to another embodiment of the present invention. In order to adjust the initial inductance value of light load and delay the decay of inductance under heavy load, the third air gap G3 and/or the fourth air gap G4 can be increased. The size of the third air gap G3 and the fourth air gap G4 can be adjusted by moving the second magnetic core 120 on the X-axis.

The first air gap G1, the second air gap G2, the third air gap G3 and the fourth air gap G4 may be selectively filled with an insulating glue layer (not shown), and the insulating glue layer may be mixed with insulating beads having sizes corresponding to the sizes of the first air gap G1, the second air gap G2, the third air gap G3 and the fourth air gap G4, so that the first magnetic core 110 and the second magnetic core 120 are fixed with appropriate air gap sizes.

Please refer to FIG. 6 and FIG. 7 , since the surfaces of the first end post 122 and the second end post 123 facing the first air gap G1 and the second air gap G2 are planes, the sizes of the first air gap G1 and the second air gap G2 on the X axis and the Z axis are consistent. However, the present invention is not limited thereto, and in other embodiments, the first air gap G1 and/or the second air gap G2 may have different sizes on the Z axis.

FIG. 8 shows a side view of a magnetic element 100b according to another embodiment of the present invention; FIG. 9 shows a side view of a magnetic element 100c according to another embodiment of the present invention.

Please refer to FIG. 8. The main difference between the magnetic element 100b of FIG. 8 and the magnetic elements 100 and 100a of FIG. 6 and FIG. 7 is that, in the present embodiment, the first end column 122b of the second magnetic core 120b has a notch 122R1 at the edge near one side of the second joint surface 112J, and the notch 122R1 penetrates the first end column 122b along the X-axis. The second end column 123b of the second magnetic core 120b has a notch 123R1 at the edge near one side of the third joint surface 113J, and the notch 123R1 penetrates the second end column 123b along the X-axis. The notch 122R1 and the notch 123R1 can be rectangular notches, so that the first air gap G1 and the second air gap G2 show a step-like change on the Z-axis.

Please refer to FIG. 9. The main difference between the magnetic element 100c of FIG. 9 and the magnetic elements 100 and 100a of FIG. 6 and FIG. 7 is that, in the present embodiment, the first end column 122c of the second magnetic core 120c has a notch 122R2 at an edge close to one side of the second joint surface 112J, and the notch 122R2 penetrates the first end column 122c along the X-axis. The second end column 123c of the second magnetic core 120c has a notch 123R2 at an edge close to one side of the third joint surface 113J, and the notch 123R2 penetrates the second end column 123c along the X-axis. The notch 122R2 and the notch 123R2 can be triangular prism-shaped notches, so that the first air gap G1 and the second air gap G2 show a gradual expansion change on opposite sides of the Z-axis.

FIG. 10 shows the inductance curves of the magnetic element of the comparative example and the magnetic elements 100, 100a, 100b of the embodiment of the present invention under different current loads, wherein the comparative example is a general magnetic element with a toroidal magnetic core. Some data are listed in Table 1. Number of coils Initial inductance value (μH) DC resistance (Mohm) Comparison Example 79 470 90.2 Magnetic element 100a 70 701 89.6 Magnetic components 100 70 481 89.6 Magnetic element 100b 70 694 89.6

Please refer to Figure 10. It can be seen from the figure and Table 1 that compared with the magnetic element of the comparative example, the magnetic element 100a can be made with fewer coils and its overall inductance is also improved. Compared with the magnetic element 100a in which the size of the third air gap G3 and the fourth air gap G4 is 0, the magnetic element 100 increases the size of the third air gap G3 and the fourth air gap G4, thereby adjusting the starting inductance value under light load and delaying the decay of inductance under heavy load. Compared with the magnetic element 100a, the first air gap G1 and the second air gap G2 of the magnetic element 100b show a step-like change on the Z axis, thereby fine-tuning the inductance curve. In general, the magnetic elements 100, 100a, 100b of the embodiments of the present invention can reduce the attenuation of the inductance and improve the overall current-withstanding strength even under heavy load conditions (such as a current greater than 9A).

Please refer to FIG. 6 , since the surfaces of the first end post 122 and the second end post 123 facing the third air gap G3 and the fourth air gap G4 are plane, the third air gap G3 and the fourth air gap G4 have the same size on the Y axis and the Z axis. However, the present invention is not limited thereto, and in other embodiments, the third air gap G3 and/or the fourth air gap G4 may have different sizes on the Z axis.

Figure 11 shows an assembly diagram of a magnetic element 100d according to other embodiments of the present invention; Figure 12A shows a schematic diagram of the second magnetic core 120d of the magnetic element 100d in Figure 11; Figure 12B shows a schematic diagram of the second magnetic core 120d in Figure 12A from another viewing angle; Figure 13 shows a schematic cross-sectional diagram of the magnetic element 100d in Figure 11 along section line 13-13'.

11, 12A, 12B and 13, the main difference between the magnetic element 100d and the magnetic elements 100 and 100a of Figures 6 and 7 is that the shape of the second magnetic core 120d is different from the second magnetic core 120. In the embodiment of Figures 6 and 7, the first end column 122 and the second end column 123 of the second magnetic core 120 are shaped like a square plate structure. In this embodiment, one side of the first end column 122d and the second end column 123d of the second magnetic core 120d has an arc structure, especially the side facing the positive direction of the X-axis (or the side close to the first joint surface 111J), and the arc structure protrudes toward the first joint surface 111J, so that the third air gap G3 and the fourth air gap (not marked) show a gradual expansion change on the opposite sides of the Z axis.

In one embodiment, as shown in FIG. 13 , the first end post 122d may contact the first joint surface 111J at the vertex of its arc structure, and be spaced apart from the first joint surface 111J on opposite sides away from the vertex, so that the size of the third air gap G3 on the Z axis changes from the center to the sides. In addition, although not shown, the second end post 123d may also contact the first joint surface 111J at the vertex of its arc structure, and be spaced apart from the first joint surface 111J on opposite sides away from the vertex, so that the size of the fourth air gap on the Z axis changes from the center to the sides. However, the present invention is not limited thereto. In another embodiment, the first end post 122d and the second end post 123d may not contact the first joint surface 111J.

In summary, the magnetic element of the present invention can form multiple air gaps between the first magnetic core and the second magnetic core, and the efficiency of the magnetic element can be adjusted according to the design requirements by using the multiple air gaps. For example, by adjusting the size and/or size change of these air gaps, the current flow that the magnetic element can withstand is changed to correspond to the inductance requirements under light and heavy loads, so as to optimize the efficiency.

Although the present invention has been described above with the embodiments, they are not intended to limit the present invention. Those with ordinary knowledge in the technical field to which the present invention belongs can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope of the attached patent application.

100,100a,100b,100c,100d: magnetic element 110: first magnetic core 111: first side column 111J: first joint surface 111R: groove portion 112: first side column 112a,113a: first wall 112b,113b: second wall 112c,113c: connecting wall 112J: second joint surface 113: second side column 113J: third joint surface 120,120b,120c,120d: second magnetic core 120S: flat surface 121: second side column 122,122b,122c,122d: first end column 122R1,122R2,123R1,123R2: notch 123,123b,123c,123d: second end post 130: coil assembly 131: wire inlet 132: wire outlet G1: first air gap G2: second air gap G3: third air gap G4: fourth air gap N1: first normal line N2: second normal line N3: third normal line S: storage space

FIG. 1 shows an assembly diagram of a magnetic element according to an embodiment of the present invention; FIG. 2 shows an exploded view of the magnetic element of FIG. 1; FIG. 3A shows a schematic diagram of a first magnetic core of the magnetic element of FIG. 1; FIG. 3B shows a schematic diagram of the first magnetic core of FIG. 3A from another perspective; FIG. 4A shows a schematic diagram of a second magnetic core of the magnetic element of FIG. 1; FIG. 4B shows a schematic diagram of the second magnetic core of FIG. 4A from another perspective; FIG. 5 shows a three-dimensional cross-sectional schematic diagram of the magnetic element of FIG. 1; FIG. 6 shows a cross-sectional schematic diagram of the magnetic element of FIG. 1; FIG. 7 shows a cross-sectional schematic diagram of a magnetic element according to another embodiment of the present invention; FIG. 8 shows a side view of a magnetic element according to another embodiment of the present invention; FIG. 9 shows a side view of a magnetic element according to another embodiment of the present invention; FIG. 10 shows the inductance curves of the magnetic element of the comparative example and the magnetic element of the embodiment of the present invention under different current loads; FIG. 11 shows an assembly diagram of the magnetic element according to other embodiments of the present invention; FIG. 12A shows a schematic diagram of the second magnetic core of the magnetic element of FIG. 11; FIG. 12B shows a schematic diagram of the second magnetic core of FIG. 12A from another perspective; and FIG. 13 shows a schematic diagram of the cross section of the magnetic element of FIG. 11 along the section line 13-13'.

100: Magnetic components

110: First magnetic core

111: First side column

111R: Groove section

112: First side post

113: Second side post

120: Second magnetic core

121: Second side column

122: First end column

123: Second end column

130: Coil set

G1: First air gap

G2: Second air gap

G3: The third air gap

G4: Fourth air gap

Claims (16)

A magnetic element, comprising: A first magnetic core, comprising a first side column, a second side column and a first side column, the first side column having a first joint surface, the first side column and the second side column being arranged on the first joint surface of the first side column, and the first side column, the second side column and the first side column forming a containing space, the first side column and the second side column respectively having a second joint surface and a third joint surface, the second joint surface and the third joint surface being arranged face to face; A second magnetic core is located in the accommodation space, the second magnetic core includes a second side post, a first end post and a second end post, the first end post and the second end post are respectively arranged at two ends of the second side post, there is a first air gap between the first end post and the second joint surface, there is a second air gap between the second end post and the third joint surface, there is a third air gap between the first end post and the first joint surface, and there is a fourth air gap between the second end post and the first joint surface; and a coil group, surrounding the second side post. A magnetic element as described in claim 1, wherein the first magnetic core is a U-shaped magnetic core and the second magnetic core is an I-shaped magnetic core. A magnetic element as described in claim 1, wherein the first side column of the first magnetic core has a groove portion, and the groove portion is recessed inward from the first joint surface. A magnetic element as described in claim 1, wherein the sizes of the third air gap and the fourth air gap are adjustable to achieve a desired inductance. A magnetic element as described in claim 1, wherein the first end post and the first joint surface are spaced apart on a first axis to form the third air gap therebetween; the second end post and the first joint surface are spaced apart on the first axis to form the fourth air gap therebetween; the first end post and the second joint surface are spaced apart on a second axis to form the first air gap therebetween; the second end post and the third joint surface are spaced apart on the second axis to form the second air gap therebetween; and the first axis is perpendicular to the second axis. A magnetic element as described in claim 5, wherein the first air gap is connected to the third air gap, and the second air gap is connected to the fourth air gap. A magnetic element as described in claim 5, wherein the first air gap and/or the second air gap have the same size on a third axis, and the third axis is perpendicular to the first axis and the second axis. A magnetic element as described in claim 5, wherein the size of the first air gap and/or the second air gap varies on a third axis, and the third axis is perpendicular to the first axis and the second axis. A magnetic element as described in claim 8, wherein the first end post has a notch penetrating along the first axis at an edge near one side of the second joint surface, and/or the second end post has a notch penetrating along the first axis at an edge near one side of the third joint surface. A magnetic element as described in claim 5, wherein the third air gap and/or the fourth air gap have consistent dimensions on a third axis, and the third axis is perpendicular to the first axis and the second axis. A magnetic element as described in claim 5, wherein the third air gap and/or the fourth air gap has a variation in size on a third axis, and the third axis is perpendicular to the first axis and the second axis. A magnetic element as described in claim 11, wherein the first end post has an arc structure, the arc structure of the first end post protrudes toward the first joint surface, and/or the second end post has an arc structure, the arc structure of the second end post protrudes toward the first joint surface. A magnetic element as described in claim 1, wherein the first joint surface has a first normal, the second joint surface has a second normal, the third joint surface has a third normal, the second normal and the third normal are orthogonal to the first normal, the first normal is parallel to a first axis, and the second normal and the third normal are parallel to a second axis. A magnetic element as described in claim 13, wherein the first end column and the second end column are respectively arranged at two ends of the second side column on the second axis. A magnetic element as described in claim 13, wherein the first side column and the second side column each include a connecting wall, a first wall and a second wall, the connecting wall connects the first wall and the second wall, the first wall and the second wall are arranged opposite to each other on a third axis, the third axis is perpendicular to the first axis and the second axis, and the first wall, the connecting wall and the second wall constitute a U-shaped side column, the second joint surface is the surface of the connecting wall of the first side column facing the accommodating space, and the third joint surface is the surface of the connecting wall of the second side column facing the accommodating space. A magnetic element as described in claim 13, wherein the second magnetic core has a flat surface on one side of the first joint surface on the first axis away from the first side column, and the coil assembly is wound from one side of the flat surface.

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