CN114188128A

CN114188128A - Magnetic components

Info

Publication number: CN114188128A
Application number: CN202010966643.7A
Authority: CN
Inventors: 张君毅; 蓝世富; 阮吕平
Original assignee: Lite On Technology Corp
Current assignee: Lite On Technology Corp
Priority date: 2020-09-15
Filing date: 2020-09-15
Publication date: 2022-03-15

Abstract

The invention provides a magnetic assembly which comprises a first magnetic core, a second magnetic core, a third magnetic core and a coil assembly. The first magnetic core comprises a plurality of first side columns and is provided with a first through hole and a first wall surface surrounding the first through hole. The second magnetic core is positioned on one side of the first magnetic core and comprises a plurality of second side columns, the first side columns of the first magnetic core face the second side columns of the second magnetic core, and the first air gaps are formed between the first side columns and the second side columns. The third magnetic core is arranged between the first magnetic core and the second magnetic core and extends into the first through hole, and a second air gap is formed between the third magnetic core and the first wall surface. The coil group is positioned in the first magnetic core and the second magnetic core and surrounds the third magnetic core.

Description

Magnetic assembly

Technical Field

The present invention relates to a magnetic device, and more particularly, to a magnetic device with improved efficiency.

Background

At present, magnetic components are widely used in devices such as power supplies, and how to manufacture high-efficiency magnetic components is a research goal of those skilled in the relevant field.

Disclosure of Invention

The present invention provides a magnetic assembly having improved efficiency.

The invention discloses a magnetic assembly, which comprises a first magnetic core, a second magnetic core, a third magnetic core and a coil assembly. The first magnetic core comprises a plurality of first side columns and is provided with a first through hole and a first wall surface surrounding the first through hole. The second magnetic core is positioned on one side of the first magnetic core and comprises a plurality of second side columns, the first side columns of the first magnetic core face the second side columns of the second magnetic core, and the first air gaps are formed between the first side columns and the second side columns. The third magnetic core is arranged between the first magnetic core and the second magnetic core and extends into the first through hole, and a second air gap is formed between the third magnetic core and the first wall surface. The coil group is positioned in the first magnetic core and the second magnetic core and surrounds the third magnetic core.

In an embodiment of the invention, the first magnetic core includes a first substrate, the first side pillars protrude from the first substrate, the first through hole penetrates through the first substrate, and the second magnetic core includes a second substrate, the second side pillars protrude from the second substrate.

In an embodiment of the invention, the third magnetic core includes a first end surface, and the first end surface is flush with an outer surface of the first substrate of the first magnetic core.

In an embodiment of the invention, the third magnetic core includes a first end surface, and the first end surface exceeds an outer surface of the first substrate of the first magnetic core.

In an embodiment of the invention, the third magnetic core includes a first end surface, and the first end surface is located between an outer surface and an inner surface of the first substrate of the first magnetic core.

In an embodiment of the invention, the second substrate of the second magnetic core has a second through hole and a second wall surface surrounding the second through hole, the third magnetic core extends into the second through hole, and a third air gap exists between the third magnetic core and the second wall surface.

In an embodiment of the invention, the second substrate has no through hole, the third magnetic core includes a second end surface, the second end surface abuts against the second substrate or is retracted relative to the second substrate, and a third air gap exists between the second end surface and the second substrate.

In an embodiment of the invention, a material of the first magnetic core is different from a material of the third magnetic core, and a material of the second magnetic core is different from a material of the third magnetic core.

In an embodiment of the invention, a saturation magnetic flux density of the third magnetic core is greater than that of the first and second magnetic cores.

In an embodiment of the invention, a cross-sectional area of the third magnetic core is smaller than a sum of top surface areas of the first side pillars of the first magnetic core, and the cross-sectional area of the third magnetic core is smaller than a sum of top surface areas of the second side pillars of the second magnetic core.

In an embodiment of the invention, the widths of the second air gap in the extending direction of the third magnetic core are uniform.

In an embodiment of the invention, the first wall surface is a partial conical surface, so that the second air gap has a different width in the extending direction of the third magnetic core.

In an embodiment of the invention, the first wall surface is a curved surface, so that widths of the second air gap in an extending direction of the third magnetic core are different.

In an embodiment of the invention, the third magnetic core has a through hole.

In an embodiment of the invention, the first side pillars include a plurality of first slopes inclining toward the third magnetic core, or/and the second side pillars include a plurality of second slopes inclining toward the third magnetic core.

In an embodiment of the invention, the first magnetic core and the second magnetic core are disposed along an extending direction of the third magnetic core, and the first through hole is a closed hole.

In an embodiment of the invention, the first magnetic core and the second magnetic core are disposed along a direction perpendicular to an extending direction of the third magnetic core, and are located beside a peripheral side of the third magnetic core, and the first through hole is a non-closed hole.

Based on the above, in the magnetic assembly of the present invention, the third magnetic core is disposed between the first magnetic core and the second magnetic core and extends into the first through hole of the first magnetic core, so that a second air gap exists between the third magnetic core and the first wall surface. The second air gap may help to increase the current flow that the magnetic assembly can withstand, helping to increase output efficiency.

Drawings

FIG. 1 is a schematic view of a magnetic assembly in accordance with an embodiment of the present invention;

FIG. 2A is an exploded schematic view of the magnetic assembly of FIG. 1;

FIG. 2B is a schematic view of a first magnetic core of the magnetic assembly of FIG. 1;

FIG. 2C is a schematic view of another perspective of FIG. 2B;

FIG. 2D is a schematic diagram of a second magnetic core of the magnetic assembly of FIG. 1;

FIG. 2E is a schematic view of another perspective of FIG. 2D;

FIG. 3 is a schematic perspective cross-sectional view of the magnetic assembly of FIG. 1;

FIG. 4 is a cross-sectional schematic view of the magnetic assembly of FIG. 1;

fig. 5-11 are cross-sectional schematic views of various magnetic assemblies according to various embodiments of the present invention;

fig. 12 is an exploded schematic view of a magnetic assembly in accordance with an embodiment of the present invention;

FIG. 13 is an assembled schematic view of a magnetic assembly in accordance with an embodiment of the present invention;

FIG. 14 is an exploded schematic view of the magnetic assembly of FIG. 13;

fig. 15 is a cross-sectional schematic view of the magnetic assembly of fig. 13.

Description of the reference numerals

D is the extending direction;

g1, G1i: first air gap;

g2, G2a, G2b, G2i, a second air gap;

g3, G3a, G3b, G3e, G3 i;

100. 100a, 100b, 100c, 100d, 100e, 100f, 100g, 100h, 100i magnetic components;

110. 110i: a first magnetic core;

111: a first substrate;

112. 112i first perforation;

113. 113b, 113i a first wall surface;

114. 114g of a first side column;

115 a top surface;

116 an outer surface;

117 an inner surface;

118, a first bevel;

120. 120i is a second magnetic core;

121. 121e is a second substrate;

122. 122i: a second perforation;

123. 123b, 123i, a second wall surface;

124. 124g of a second side column;

125, a top surface;

126, an outer surface;

127, an inner surface;

128, a second inclined plane;

130. 130c, 130d, 130e, 130f a third magnetic core;

132 a first end face;

134 is a second end face;

136, through holes;

140, a coil assembly;

145, a winding frame.

Detailed Description

Reference will now be made in detail to exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the description to refer to the same or like parts.

Fig. 1 is a schematic diagram of a magnetic assembly according to an embodiment of the present invention. Fig. 2A is an exploded schematic view of the magnetic assembly of fig. 1. Fig. 2B is a schematic diagram of a first core of the magnetic assembly of fig. 1. Fig. 2C is a schematic view of another perspective of fig. 2B. Fig. 2D is a schematic diagram of a second core of the magnetic assembly of fig. 1. Fig. 2E is a schematic view of another view of fig. 2D. Fig. 3 is a schematic perspective cross-sectional view of the magnetic assembly of fig. 1. Fig. 4 is a cross-sectional schematic view of the magnetic assembly of fig. 1.

Referring to fig. 1 to 4, the magnetic assembly 100 of the present embodiment includes a first magnetic core 110, a second magnetic core 120, a third magnetic core 130, a coil assembly 140 and a bobbin 145. In the present embodiment, the first magnetic core 110 includes a first substrate 111 and a plurality of first side legs 114 protruding from the first substrate 111. The first substrate 111 has a first through hole 112 and a first wall 113 surrounding the first through hole 112. The first through hole 112 is located at the center of the first substrate 111 and is a closed hole.

The second magnetic core 120 is disposed on one side of the first magnetic core 110, and includes a second substrate 121 and a plurality of second side pillars 124 protruding from the second substrate 121. The second substrate 121 of the second magnetic core 120 has a second through hole 122 and a second wall 123 surrounding the second through hole 122. The second through hole 122 is located at the center of the second substrate 121, corresponding to the first through hole 112, and the second through hole 122 is a closed hole.

The first side legs 114 of the first core 110 face the second side legs 124 of the second core 120. As shown in fig. 3 and 4, a first air gap G1 is formed between the first side pillars 114 and the second side pillars 124. The first air gap G1 is optionally filled with an insulating glue (not shown) to fix the first magnetic core 110 and the second magnetic core 120. The first air gap G1 is used to adjust the inductance and increase the current flow that the magnetic assembly 100 can withstand, thereby improving the output efficiency of the power supply.

In the present embodiment, the materials and shapes of the first magnetic core 110 and the second magnetic core 120 are the same, but in other embodiments, the materials and/or shapes of the first magnetic core 110 and the second magnetic core 120 may be different.

The third magnetic core 130 is cylindrical, and is disposed between the first magnetic core 110 and the second magnetic core 120 and extends into the first through hole 112 of the first magnetic core 110 and the second through hole 122 of the second magnetic core 120. As shown in fig. 3 and 4, in the present embodiment, since the third magnetic core 130 is independent from the first magnetic core 110 and the second magnetic core 120, a second air gap G2 exists between the third magnetic core 130 and the first wall 113, and a third air gap G3 exists between the third magnetic core 130 and the second wall 123. The second gap G2 and the third gap G3 can adjust the current flow that the magnetic assembly 100 can bear, thereby improving the output efficiency of the power supply.

The coil assembly 140 and the bobbin 145 are disposed in the first magnetic core 110 and the second magnetic core 120, and the coil assembly 140 is disposed on the bobbin 145 and surrounds the third magnetic core 130. In the present embodiment, the coil assembly 140 is a metal coil, but the shape or type of the coil assembly 140 is not limited thereto, and may be any coiled conductor.

In the present embodiment, the material of the third core 130 is different from the material of the first core 110 and the second core 120. The third core 130 may be made of a material with a higher saturation magnetic flux density, and the saturation magnetic flux density of the third core 130 is greater than the saturation magnetic flux densities of the first core 110 and the second core 120.

For example, the first and second

magnetic cores

110 and 120 may be made of an mn-au alloy, and the third magnetic core 130 may be made of an fe-ni alloy or an sendai alloy. Of course, the materials of the first, second and third

magnetic cores

110, 120 and 130 are not limited thereto.

In an embodiment, the saturation magnetic flux density of the first magnetic core 110 and the second magnetic core 120 may be 4000T, and the saturation magnetic flux density of the third magnetic core 130 may be 15000T, for example. The higher the saturation magnetic flux density is, the larger the amount of current that can be tolerated, and the larger the output power. Therefore, in the embodiment, since the third magnetic core 130 is independent of the first magnetic core 110 and the second magnetic core 120, the third magnetic core 130 can be made of a material with a higher saturation magnetic flux density, so as to effectively improve the output efficiency of the power supply. In addition, the first magnetic core 110 and the second magnetic core 120 may be made of a material having a low saturation magnetic flux density, so as to reduce the cost.

In addition, since the third magnetic core 130 may be made of a material with a larger saturation magnetic flux density, the cross-sectional area of the third magnetic core 130 (e.g., the area of the first end surface 132 of the third magnetic core 130) may be smaller than the sum of the areas of the top surfaces 115 (fig. 2C) of the first side pillars 114 of the first magnetic core 110, and the cross-sectional area of the third magnetic core 130 may be smaller than the sum of the areas of the top surfaces 125 (fig. 2E) of the second side pillars 124 of the second magnetic core 120. In this way, the volume of the third core 130 can be reduced, and the overall volume of the magnetic component 100 can be correspondingly reduced, which is more suitable for small-sized devices.

As shown in fig. 3 and 4, in the present embodiment, the first wall surface 113 and the second wall surface 123 are partial conical surfaces, for example, the first wall surface 113 is wide at the top and narrow at the bottom, and the second wall surface 123 is narrow at the top and wide at the bottom, so that the second air gap G2 is wide at the top and narrow at the bottom in the extending direction D of the third core 130, and the third air gap G3 is narrow at the top and wide at the bottom in the extending direction D of the third core 130. Therefore, the second air gap G2 and the third air gap G3 have various widths in the extending direction D of the third magnetic core 130.

Of course, in other embodiments, the second air gap G2 may be narrower at the top and wider at the bottom in the extending direction D of the third core 130, or/and the third air gap G3 may be narrower at the top and wider at the bottom in the extending direction D of the third core 130, which is not limited in the drawings. Alternatively, the second air gap G2 and the third air gap G3 may be stepped, and are not necessarily tapered or divergent in the extending direction D of the third magnetic core 130.

Fig. 5-11 are cross-sectional schematic views of various magnetic assemblies according to various embodiments of the present invention. Referring to fig. 5, a main difference between the magnetic element 100a of fig. 5 and the magnetic element 100 of fig. 4 is that, in the present embodiment, the widths of the second air gap G2a and the third air gap G3a in the extending direction D of the third magnetic core 130 are the same.

Referring to fig. 6, a main difference between the magnetic assembly 100b of fig. 6 and the magnetic assembly 100 of fig. 4 is that in the present embodiment, the first wall 113b and the second wall 123b are curved, so that the widths of the second air gap G2b and the third air gap G3b in the extending direction D of the third magnetic core 130 are different.

Referring to fig. 7, a main difference between the magnetic component 100c of fig. 7 and the magnetic component 100 of fig. 4 is that, in fig. 4, the third magnetic core 130 includes a first end surface 132 and a second end surface 134, the first end surface 132 is flush with the outer surface 116 of the first substrate 111 of the first magnetic core 110, and the second end surface 134 is flush with the outer surface 126 of the second substrate 121 of the second magnetic core 120.

In the present embodiment, the first end surface 132 of the third magnetic core 130c exceeds the outer surface 116 of the first substrate 111 of the first magnetic core 110, and the second end surface 134 exceeds the outer surface 126 of the second substrate 121 of the second magnetic core 120.

Referring to fig. 8, the main difference between the magnetic component 100d of fig. 8 and the magnetic component 100 of fig. 4 is that the first end surface 132 and the second end surface 134 of the third magnetic core 130d are retracted, such that the first end surface 132 of the third magnetic core 130d is located between the outer surface 116 and the inner surface 117 of the first substrate 111 of the first magnetic core 110, and the second end surface 134 is located between the outer surface 126 and the inner surface 127 of the second substrate 121 of the second magnetic core 120.

It should be noted that, in other embodiments, the first end face 132 of the third

magnetic core

130, 130d may be higher than the outer surface 116 of the first substrate 111, and the second end face 134 may be flush with or lower than the outer surface 126 of the second substrate 121. The form of the third

magnetic cores

130, 130d is not limited to the above.

Referring to fig. 9, the main difference between the magnetic component 100e of fig. 9 and the magnetic component 100 of fig. 4 is that, in the present embodiment, the second substrate 121e has no through hole, and the second end 134 of the third magnetic core 130e abuts against the second substrate 121. As can be seen from the enlarged view, a third air gap G3e still exists between the second end surface 134 of the third magnetic core 130e and the inner surface 127 of the second substrate 121 e.

In other embodiments, the second end surface 134 of the third magnetic core 130e may also be recessed relative to the second substrate 121e, and a larger third air gap G3e exists between the second end surface and the second substrate 121 e.

Referring to fig. 10, a main difference between the magnetic assembly 100f of fig. 10 and the magnetic assembly 100 of fig. 4 is that, in the present embodiment, the third magnetic core 130f has a through hole 136, and the through hole 136 facilitates heat dissipation, so that the heat dissipation efficiency can be effectively improved. In this embodiment, the third magnetic core 130f may be made of a material with a higher saturation magnetic flux density to increase the magnetic flux density, so as to compensate for the reduced cross-sectional area of the through hole 136 and maintain the magnetic flux of the third magnetic core 130 f.

Referring to fig. 11, a main difference between the magnetic assembly 100g of fig. 11 and the magnetic assembly 100 of fig. 4 is that, in the present embodiment, the first side pillars 114g include a plurality of first inclined surfaces 118 inclined toward the third magnetic core 130. The distance between the first side leg 114g and the coil assembly 140 in the extending direction D of the third magnetic core 130 is changed by the design of the first inclined surface 118, so that different magnetic flux states between the first side leg 114g and the coil assembly 140 can be provided.

Likewise, the second side legs 124g include second slopes 128 inclined toward the third magnetic core 130. The distance between the second side leg 124g and the coil assembly 140 in the extending direction D of the third magnetic core 130 is changed by the design of the second slope 128, so that different magnetic flux states between the second side leg 124g and the coil assembly 140 can be provided. Of course, in other embodiments, the magnetic assembly 100g may have only the first leg 114g with the first inclined surface 118 or only the second leg 124g with the second inclined surface 128.

Fig. 12 is an exploded view of a magnetic assembly in accordance with an embodiment of the present invention. Referring to fig. 12, a main difference between the magnetic assembly 100h of fig. 12 and the magnetic assembly 100 of fig. 2A is that in fig. 2A, the coil assembly 140 is formed by winding a metal wire, and in this embodiment, the coil assembly 140h is a multi-layer ring structure formed by pressing metal sheets.

Fig. 13 is an assembled view of a magnetic assembly according to an embodiment of the invention. Fig. 14 is an exploded schematic view of the magnetic assembly of fig. 13. Fig. 15 is a cross-sectional schematic view of the magnetic assembly of fig. 13. Referring to fig. 13 to 15, the main difference between the magnetic assembly 100i of fig. 13 and the magnetic assembly 100 of fig. 2A is that in fig. 2A, the first magnetic core 110 and the second magnetic core 120 are vertically disposed along the extending direction D of the third magnetic core 130, the first air gap G1 is a horizontal gap, and the first through hole 112 is a closed hole.

In the present embodiment, the first core 110i and the second core 120i are located on the peripheral side of the third core 130 along the direction perpendicular to the extending direction D of the third core 130, and are disposed on the left and right. The first air gap G1i is a vertical gap, and the first through hole 112i and the second through hole 122i are non-closed holes.

As can be seen in fig. 15, the first magnetic core 110i has two first through holes 112i, and the second magnetic core 120i has two second through holes 122 i. The first through hole 112i and the second through hole 122i form a ring-shaped hole, and a second air gap G2i exists between the first wall surface 113i near the first through hole 112i and the second wall surface 123i near the second through hole 122i and the third magnetic core 130.

The first through hole 112i and the second through hole 122i form an annular hole, and a third air gap G3i exists between the first wall surface 113i beside the first through hole 112i and the second wall surface 123i beside the second through hole 122i and the third magnetic core 130.

Similarly, the second gap G2i and the third gap G3i can help to increase the current flow that the magnetic assembly 100i can bear, thereby helping to increase the output efficiency of the power supply. In addition, since the third magnetic core 130 is independent of the first magnetic core 110i and the second magnetic core 120i, the third magnetic core 130 can be made of a material with a high saturation magnetic flux density, so as to effectively improve the output efficiency of the power supply.

In summary, in the magnetic assembly of the present invention, the third magnetic core is disposed between the first magnetic core and the second magnetic core and extends into the first through hole of the first magnetic core, so that a second air gap exists between the third magnetic core and the first wall surface. The second air gap may help to increase the current flow that the magnetic assembly can withstand, helping to increase output efficiency.

Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A magnetic assembly, comprising:

the first magnetic core comprises a plurality of first side columns and is provided with a first through hole and a first wall surface surrounding the first through hole;

a second magnetic core located at one side of the first magnetic core and including a plurality of second side legs, the plurality of first side legs of the first magnetic core facing the plurality of second side legs of the second magnetic core, and a first air gap formed between the plurality of first side legs and the plurality of second side legs;

a third magnetic core disposed between the first magnetic core and the second magnetic core and extending into the first through hole, wherein a second air gap is formed between the third magnetic core and the first wall surface; and

a coil assembly positioned within the first and second cores and surrounding the third core.

2. The magnetic component of claim 1, wherein the first magnetic core includes a first substrate, the first side pillars protrude from the first substrate, the first through hole penetrates through the first substrate, and the second magnetic core includes a second substrate, and the second side pillars protrude from the second substrate.

3. The magnetic component of claim 2, wherein the third magnetic core comprises a first end face that is flush with an outer surface of the first substrate of the first magnetic core.

4. The magnetic assembly of claim 2, wherein the third magnetic core includes a first end face that protrudes beyond an outer surface of the first substrate of the first magnetic core.

5. The magnetic component of claim 2, wherein the third magnetic core includes a first end face positioned between an outer surface and an inner surface of the first substrate of the first magnetic core.

6. The magnetic assembly of claim 2, wherein the second substrate of the second core has a second through hole and a second wall surrounding the second through hole, the third core extends into the second through hole, and a third air gap is formed between the third core and the second wall.

7. The magnetic component of claim 2, wherein the second substrate is free of perforations, and wherein the third magnetic core comprises a second end face that abuts or is recessed relative to the second substrate with a third air gap therebetween.

8. The magnetic component of claim 1, wherein the first magnetic core is made of a different material than the third magnetic core, and the second magnetic core is made of a different material than the third magnetic core.

9. The magnetic assembly of claim 1, wherein a saturation flux density of the third magnetic core is greater than a saturation flux density of the first and second magnetic cores.

10. The magnetic component of claim 1, wherein a cross-sectional area of the third magnetic core is less than a sum of top surface areas of the first plurality of side legs of the first magnetic core, and wherein a cross-sectional area of the third magnetic core is less than a sum of top surface areas of the second plurality of side legs of the second magnetic core.

11. The magnetic component of claim 1, wherein the second air gap has a uniform width in a direction of extension of the third core.

12. The magnetic component of claim 1, wherein the first wall is a partial cone such that the second air gap has a different width in a direction of extension of the third core.

13. The magnetic component of claim 1, wherein the first wall is curved such that the second air gap has a different width in a direction of extension of the third core.

14. The magnetic component of claim 1, wherein the third magnetic core has a through hole.

15. The magnetic component of claim 1, wherein the first plurality of side legs comprise a first plurality of ramps that slope toward the third magnetic core, and/or wherein the second plurality of side legs comprise a second plurality of ramps that slope toward the third magnetic core.

16. The magnetic assembly according to claim 1, wherein the first magnetic core and the second magnetic core are disposed along an extending direction of the third magnetic core, and the first through hole is a closed hole.

17. The magnetic assembly according to claim 1, wherein the first magnetic core and the second magnetic core are disposed along a direction perpendicular to an extending direction of the third magnetic core, and are located beside a peripheral side of the third magnetic core, and the first through hole is a non-closed hole.