TWI357608B - Gapped core structure for magnetic components - Google Patents

Description

1357608 IX. Description of the Invention: TECHNICAL FIELD OF THE INVENTION The present invention relates generally to the manufacture of electronic components, and more particularly to the fabrication of magnetic components such as inductors. [Prior Art] A plurality of magnetic components including, but not limited to, an inductor and a transformer include at least a winding disposed around a magnetic core. In some of these components, the core assembly is made of a ferrite core having a gap and bonding. In use, the gap between the cores is required to store energy in the core, and the gap effects include, but are not limited to, magnetic properties of the open circuit inductance and DC bias characteristics. = • f In small components, creating a uniform gap between the cores is important for consistent manufacturing of reliable, quality magnetic components. In some examples, epoxy resins have been used in conjunction with ferrite cores for making bonded core assemblies for magnetic components. In an attempt to consistently impart a gap B temple to the core, sometimes non-magnetic beads (usually glass spheres) are mixed with the binder material and the non-magnetic beads are placed between the cores. A gap is formed. When cured by heat, the epoxy combines the cores and the beads open up into gaps. However, the combination is primarily dependent on the viscosity of the epoxy resin, the epoxy resin and the beads of the adhesive mixture applied between the cores, and in some applications, the bonded cores are not sufficiently bonded. For its § m is also used for the top stage, and it has been proved that it is extremely difficult to control the ratio of the epoxy resin to the glass sphere in the adhesive mixture. In a magnetic element of the type, a non-magnetic spacer material is placed between the two halves of the magnetic core + the heliocentric, and then the two halves are fastened together to separate the material of the partition between 118769.doc ^08 Hold in place. The spacer material is usually made of paper or a polyester film. Usually, the two halves of the anger and the spacer are fastened to each other using a belt wound around the two halves, wherein the two halves are fastened at the same time using an adhesive or the two halves are fastened using a central pliers and Keep the gap between the two halves. Multiple pieces (two or more) of spacer material are rarely used, because the problem of keeping the structure close to it becomes extremely complicated, difficult, and blameless. The re-type magnetic element includes a gap that is ground into a half core, and the remaining area of the half core is fastened to the other half using any of the techniques described above. Yet another method of creating a gap in the core structure begins with a single piece core and cuts the sheet material from the core (typically an annular wire core). The gap is usually filled with an adhesive or epoxy to restore the strength and shape of the core. Recently, a composite magnetic ceramic ring wire has been developed which includes a multilayer magnetic structure separated by a non-magnetic layer to form a gap. See, for example, U.S. Patent No. 6,162,311. This eliminates bonding materials (e.g., adhesives) and external gap materials (e.g., spacers) for the magnetic core structure. In either of the above devices, the conductor is typically placed through the core to lightly couple energy into the core in the form of magnetic flux, and the flux lines pass through and around the gap to complete the magnetic path in the core. If the conductor intersects the flux line, then the loop, ώ, ώ is induced in the conductor. ^ ^ When the current circulates, the resistance of the conductor generates heat, which reduces the efficiency of the magnetic element. Moving the conductor away from the magnetic flux line reduces the amount of energy that is lightly coupled to the conductor and thus increases component efficiency' but this typically requires an increase in component size (which is undesirable from a manufacturing point of view). 118769.doc 1357608 and 'The known magnetic elements are typically assembled on a single-core structure. When using multiple inductors, for example, the core entities must be separated to prevent interference in each other. 70 pieces of separation occupy valuable space on the printed circuit board. It is therefore desirable to provide for board applications - magnetic components that have increased efficiency and improved manufacturability without increasing the amount of space that does not occupy an undue amount of space on the printed circuit board. Field [Embodiment]

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of an exemplary gap magnetic core structure for a magnetic component such as an inductor including a gap anger structure, a variable (four), and other magnetic components. The core structure 10 includes a plurality of magnetic layers 12 configured in a stack, wherein a non-magnetic layer 14 extends between the magnetic layers 12 and separates two of the magnetic layers 12 to form therein - an integrated gap to interrupt one The magnetic path through the core structure 10 . As illustrated in Figure 1, the core structure 10 is adapted to form a single magnetic element, such as an inductor. The core structure 10 is constructed by combining a raw (unfired) magnetic ceramic material layer forming the magnetic layer 12 with a raw non-magnetic ceramic core material layer forming the non-magnetic layer 14. The magnetic ceramic material provides a magnetic core while the non-magnetic ceramic material acts as a gap. A region of the multilayer ceramic material of the core structure 10 is removed to create a region or opening 通过 6 through the core structure for the conductor component (not shown in Figure 1). In the illustrated embodiment, the opening 16 is generally rectangular and is defined by the peripheral edge 15 of the magnetic layer 12 and the peripheral edge 18 of the non-magnetic layer 14. The side surface 17 extends from the edge 15 of the magnetic layer 12 and the top surface 19 extends from the edge 18 of the non-magnetic layer 14 to form an internal aperture through the core structure 1 . In another embodiment 118769.doc, the opening 16 and/or the aperture can be made in another shape instead of the rectangular shape illustrated in FIG. Once the magnetic and non-magnetic layers 12, 14 are stacked to a suitable thickness and bonded together (such as by Schott's known lamination process), according to known techniques, such as known perforation processes An opening 丨 6 is formed. The core structure 1,|) is then fired to produce the final shape and properties of the core structure. Therefore, the gap magnetic core k is a single structure. In the case of tightly controlled inductance values, the gap size can be tightly controlled in terms of mass production size. The monolithic structure of the mountain magnetic core structure 10 provides a number of manufacturing advantages. By way of example, σ, in addition to adhesive bonding and external gap materials, as well as associated costs and difficulties, and thus the monomer structure is less subject to separation. The integrated gap structure also allows for tightly controlled inductance values' and multiple small gaps (instead of one of the conventional core structures to two larger gaps) to reduce the placement of conductor material in the core in use. Flux loss and heat loss. In addition, the introduction of the crevice is required for any machining operations. Therefore, the resulting magnetic π member including the core structure i 0 is stable and can maintain tight control of the gap width. A wide variety of ferrite materials can be used as the magnetic medium for forming the magnetic steep layer 12 in the core structure 丨0. Exemplary ferrite materials include manganese zinc ferrite (and especially powder ferrite), nickel zinc ferrite, lithium zinc ferrite, magnesium manganese ferrite, which are commercially available and can be obtained quite widely. Body and its similar ferrite. For the non-magnetic layer 4, a variety of ceramic materials can be used, including, for example, alumina, alumina glass mixture, cordierite stellite glass mixture, mullite, mullite glass Mixture oxidation oxidization, yttria glass mixture 'barium titanate and other titanic acid HS769.doc 1357608 ^block talc, a mixture of ferrite and non-magnetic ceramics, and similar to non-co-fired materials Magnetic or weakly magnetic ceramic material. Adding the glass phase to the non-magnetic ceramic allows modification of the sintering temperature and firing shrinkage of the non-magnetic ceramic. This is important because non-magnetic ceramics must closely match the thermal properties of the magnetic phase (i.e., ferrite). If the firing shrinkage of the two materials does not match very well, the component may operate unsatisfactorily. Although the embodiment illustrated in FIG. 1 includes three magnetic layers 12 and a non-magnetic layer 14, it should be understood that more or less magnetic layers may be employed in alternative embodiments without departing from the scope of the present invention. 12 and more or less non-magnetic layers 14. In addition, although the core structure (7) is illustrated as a generally rectangular structure in Figure i, it should be understood that other shapes for use with the core structure (7) may be employed in alternative embodiments including, but not limited to, this Ring-shaped lines are known in the art. The type of ferrite used in the magnetic layer 12 and the thickness of the non-magnetic layer 14 are practical. The magnetic properties of σ, 1 〇, and finally the properties of the resulting magnetic element using the magnetic layer 12. For example, the end loss loss can be varied by changing the starting ferrite composition, which is particularly advantageous for reducing > powder loss in the case of switching voltage regulator elements. The effective magnetic permeability (another important property) is largely controlled by the thickness of the non-magnetic layer 14. Figure 2 is a side elevational view of the core structure 1〇 equipped with a conductor part 2〇. In an exemplary embodiment, the conductor members 2 are made of a known electrically conductive material and are formed or bent at their respective ends after passing through the conductor openings 16 (shown in Figure 1). In the illustrative embodiment of FIG. 2, core structure 1 and conductor component 20 are highly suitable for forming an inductor. The assembly of the core structure 1 and the 118769.doc 1357608 conductor part 20 can be easily automated as needed. A plurality of conductor members 20 can be inserted into the core structure 1 as a single lead frame, which is then formed and trimmed into a finished product. Therefore, the high-capacity halo magnetic element can be efficiently manufactured at a much lower cost than, for example, a known inductor. 3 is a schematic cross-sectional view of a core structure 1 and a conductor component 20 illustrating a conductor component 2 that is in contact with the non-magnetic layer 14 and supported by the non-magnetic layer 且4 and that is otherwise substantially centered relative to the conductor opening 16. Hey. That is, the conductor members 2 邻接 are adjacent to the top surface 19 of the non-magnetic material 14 but spaced apart from the side edges 15 of the magnetic material 12 by substantially equal distances within the openings 16. Therefore, the non-magnetic gap extends directly below the conductor part 20 and the conductor part 2 is spaced apart from the inner surface 17 of the opening 16. As illustrated in one exemplary embodiment of FIG. 3, the shape of the conductor member 2 is complementary to the conductor opening 16, 20 and each of the conductor openings 16, and thus, in one embodiment, the conductor component is transverse. The cross section is generally rectangular. However, it should be understood that conductor parts 2 and guides may be employed in alternative embodiments of the invention.

The conductor part 20 and the conductor opening 16 need not have complementary shapes to achieve the example benefits of the present invention.

On the core structure 10. The magnetic flux lines of structure 10, and in particular Figure 4, schematically illustrate the application/mains of the core knot nS769.doc 1357608 in use, the 3⁄4 'conductor part 2 〇 does not intersect the flux lines. Therefore, the induced current in the conductor part 20 is reduced, the associated heat loss is avoided, and the efficiency of the magnetic element is increased. Therefore, the component efficiency is increased in the case of a compact component size.

As will be appreciated by those skilled in the art, component efficiency is most important at higher switching frequencies. The above structure with single turn conductor component 20 is therefore particularly suitable for higher frequency applications. However, it should be understood that in alternative embodiments of the present invention, conductive members having multiple turns may equally be employed. Fig. 5 is a view showing a second embodiment of the gap core structure 3A of the multi-gap core structure. Stacking the layers 12, 12 of the magnetic material layer and the non-magnetic material as described above into a single structure can produce a plurality of magnetic elements on the single or unitary core structure 3 as described above. Therefore, when conductive parts such as conductor parts 2 (shown in FIGS. 2 and 3) are placed through the opening 16 or when the conductive parts are additionally formed on the surface of the g structure 3G, Two of the inductors,

Two or more magnetic elements, for example, are constructed into a core structure 30 such as the core structure illustrated in FIG. The use of a full volume core structure 3G for multiple magnetic components results in lower cost because the packaging and handling of single-parts is less expensive than processing many components. Since the placement of fewer components should result in cost savings, the overall system cost can also be reduced. A further benefit is that the individual magnetic components (e.g., the single-inductors shown in Figures 2 and 3) are combined with a reduced core area for the reduced area on the board. Integrating a single-core (4) multiple inductors takes up less space than a significant number of individual components and cores, primarily because the physical voids required for individual 7L components are not integrated core structures."8769.doc 1357608 problem.

As illustrated in Fig. 5, the core structure 3 is made of a series of stacked magnetic layers 12 which are divided by at least one non-magnetic layer bucket. The magnetic layers are horizontally extended and vertically stacked, and a plurality of conductor openings 16 are formed in the stacked magnetic layers and non-magnetic layers 2, 14. The conductor openings σ16 are separated by a vertically extending non-magnetic layer or insulating layer 32, and the vertically extending insulating layer 32 is combined with the vertically stacked magnetic and non-magnetic layers 12, 14, wherein each of the conductor openings 16 resides: the magnetic The layers are in the non-magnetic layers 12, 14. Thus, the core structure 3〇 can be identified as a plurality of core structures 10 (shown in Figures! through Figure 4) that are attached to each other in a side-by-side configuration to form a larger core structure 3 〇. The vertically extending insulating layer 32 may be bonded between the stacked layers 12, 14 before or after the opening 16 is formed, and the core structure 30 is fired as a unitary structure into its final form.

Once completed, the conductor opening 16 is provided with conductive features, such as the conductor component 20 described above, to form a plurality of magnetic components that are operable from the same single core structure. This results in an overall less expensive solution than when using separate components such as inductors, especially when using automated component placement equipment. The combined inductor structure on the core 3 will use less space on the board than multiple individual inductors because no physical interference or "keep-om" regions are required. In addition, the use of a single magnetic core structure for multiple conductor parts allows the inductance values to be tracked to each other because the heating of individual inductors also affects other inductors on the same structure. The core structure 30 is particularly well suited for use in multiple voltage regulator modules (VRMs) typically used in high performance, higher current applications. The total current delivered to the load in the VRM is the sum of each VRM zone. Since many inductors can be used in the voltage regulation circuit, one or more inductors can be advantageously combined into a single package as facilitated by the core structure 30. Although the stacked layers 12, 14 of the core structure 30 include four magnetic layers 12 and a non-magnetic layer 14, it will be appreciated that more than one non-magnetic layer 14 and more or more may be employed without departing from the scope of the present invention. Less magnetic layer 12. Additionally, as described above with respect to the core 10, the core structure 3 does not need to have a rectangular shape and does not need to have a rectangular conductor opening to achieve the example benefits of the present invention, and thus, in different embodiments, the total core structure 3 can be / or the conductor opening 16 takes a variety of shapes. Figure 6 is a third embodiment of an exemplary core structure 5A in which a plurality of core structures are stacked on top of each other and separated by a non-magnetic insulating layer 52. In the illustrated embodiment, 'each core structure includes two non-magnetic layers U sandwiched between magnetic layers 12, and an insulating layer 52 extends between each core structure and is substantially flattened per anger structure Layers 12, 14. The non-magnetic layer Μ defines the opposite side of the conductor opening 16. The insulating layer 52 may be bonded between the stacked layers 12, 14 before or after the opening 16 is formed, and the core structure 5 is fired into its final form as a unitary structure. Although the stacked layers 12, 14 of the core structure 5G comprise three magnetic layers 12 and two non-magnetic layers 14', it will be appreciated that a greater or lesser number of non-magnetic layers may be employed without departing from the material of the present invention. 14 and a greater or lesser number of magnetic I. green layers 12. Additionally, as described above with respect to core structure %, the anger structure 5 〇 need not have an overall rectangular shape and does not need to have a rectangular conductor opening to achieve the example benefits of the present invention' and thus in different embodiments, the entire core structure 3 0 And/or the conductor opening 16 is of a variety of shapes. 118769.doc 1357608 Although the illustrated embodiment is constructed to include three magnetic elements in a unitary core structure, it should be understood that three or more or fewer magnetic elements may be used in other embodiments and/or alternative embodiments. Or circuits are combined into a single structure. In addition to the structural differences, the core structure 5 provides substantially the same advantages as the core structure 3 (shown in Figure 5). A gap core structure for producing a magnetic element such as an inductor, a transformer or other component is thus provided. Avoiding bonding and external gap materials in conventional core structures and improving electrical efficiency by reducing a small amount of gaps (instead of one to two larger gaps) to reduce edge flux losses in the conductor material, and the structure allows for transposition Tightly controlled inductance value. The gap is placed such that the edge flux can be placed away from the conductor, resulting in maximum efficiency, and multiple inductors can be assembled onto a single core structure, reducing overall cost and size. 7 through 9 illustrate another embodiment of a gap core structure.i 〇〇 for a magnetic component, such as an inductor, transformer, and the like that includes a gap core structure while providing benefits similar to those of structures 30 and 50 described above. Other magnetic components. Similar to structures 30 and 50, the gap core structure 100 completely obviates the external gap material and associated bonding materials and adhesives in conventional gap core structures commonly used in surface mount components in circuit board applications. Therefore, the reliability problem associated with the separation of a plurality of core members that are combined with the conventional core structure is avoided. Moreover, the manufacture of the core structure 100 is simplified compared to conventional core structures, and space savings can be realized when the gap core structure 1 is mounted to a circuit board. Figure 7 is a side elevational view of the gap core structure 100, and Figures 8 and 9 are bottom and cross-sectional views, respectively, of the gap 118769.doc] 4 1357608 core structure 100. Referring now to Figures 7-9, the core structure 100 can include a generally rectangular body 102 having opposing ends 104 and 106, relative to each other extending between the end faces 1 〇 4 and 1 〇 6 Side edges 107 and 108, and between end faces 104 and 106 and between side edges 1〇7 and 1〇8 and between interconnecting end faces 104 and 1〇6 and at the top of side edges 1〇7 and 1〇8 Surface and bottom surfaces 110 and 112 » body 1 2 may be elongated and may be defined by longitudinal axis 114 and transverse axis 116, as illustrated in the figures, side edges i 〇 7 and 108 and top and bottom surfaces 110 and 112 extends parallel to the longitudinal axis 114 and the end faces 104 and 106 extend generally parallel to the transverse axis 116. Although an exemplary rectangular shape of the body 102 is illustrated, it should be understood that in other embodiments, the body may be utilized as needed! 02 alternative shapes. The body 102 can be formed in a single piece construction and made of a known magnetic medium or material, including any of the ferrite materials mentioned above in an exemplary embodiment. . Known processes or techniques can be used to fabricate the body 102. It should be noted that and unlike the core structures 3 and 5 described above, in the configuration of the core structure 100, the core structure 1 does not include a non-magnetic material such as the non-magnetic layers 14 and 32 described above. That is, the body 1〇2 of the core structure is made of a uniform magnetic I·green material without a spacer or a piece of non-magnetic or insulating material as a single monomer having relatively constant magnetic properties throughout the body i 02 Pieces, rather than the manner described above with respect to core structures 30 and 50, are formed from different material monomers. Further, and in an exemplary embodiment, the body is entirely composed of a magnetic material opposite to a composite material such as a so-called distributed air gap core material having a powdery iron and a resin binder mixed with each other at a particle level. The gap effect is produced under the condition that the discrete gaps in the structure are not formed 118769.doc 15 1357608. However, in other embodiments, composite materials may be used as desired.

Conductor openings 118, 120 (which may be formed in body 102, and as best seen in Figure 9, openings 118, 12'' may extend completely through body 102 between side edges 1〇7 and 1〇8. Each of the 118, 120 and the side edges 1〇7, 1〇8 and the top surface of each of the side edges 1〇7 and 1〇8 are spaced apart from the bottom surface 11〇, 112 and located at the side edge 1〇7 Between the top and bottom surfaces 110, 112 between the ι〇8 and each of the side edges 107 and 108, the conductor openings 118, 120 each extend generally orthogonally or perpendicular to the sides 1〇7 and ι8, And each is positioned in spaced relation to the outer periphery of the side edges 107, 1 , 8 which are defined by the top and bottom surfaces 11 and 112 and the side edges 107 and 108 in the illustrated embodiment. The conductor openings ι 8 , 120 are each located at an internal position with respect to the outer periphery of the side edges 1〇7 and 1〇8.

While other shapes of openings may be utilized in other embodiments, the conductor openings 118 and 120 may be, for example, rectangular openings that are elongated in a direction parallel to the longitudinal axis 114. The openings 118, 12A may be integrally formed in the body 102 according to known methods, including, but not limited to, molding and/or machining techniques familiar to those skilled in the art. Although two openings 118, 120' are illustrated in Figures 7 through 9, it should be understood that a greater or lesser number of openings 11 8 and 12 可 may be provided in alternative embodiments. Discrete non-magnetic gaps 122, 124 may also be integrally formed in body 1"2, and each of gaps 122, 124 may be associated with one of conductor openings 118, 12A. The gap m' 124 is physically formed in, for example, the body 1〇2 via a known molding and/or machining technique 8769.doc 760^7608. It should be noted that the outer gap material and associated bonding material and bonding sword are not used in any way to form the gaps 122, 124, and the gaps 122, 124 lack any filler material (except for air). That is, the gaps 122, 124 are formed without the use of an insulator material (sometimes referred to as an outer gap material) applied to the body in the exemplary embodiment. However, it should be understood that in an alternate embodiment, the gaps 122, 124 may be filled with non-magnetic material as appropriate while still achieving some of the benefits of the present invention. In an exemplary embodiment' and as best shown in Figure 7, the gaps 122, I24 may extend across the respective conductor openings 118, 120. For example, each of the gaps 122, 124 can have opposite ends 126 and 128. An end 126 terminates at each of the conductor openings 118, 12 and opens to the respective conductor openings 118, 120, thereby placing the ends 126 of the gaps 122, 124 in fluid communication with the respective conductor openings 118 and 120. The opposite ends I28 of each of the gaps 122, 124 extend to the periphery of the side edges 107, 1 〇 8 and more specifically to the bottom surface 112. Each gap 22, 124 generally bisects the conductor openings 122, 124 and extends orthogonally or perpendicular to the conductor opening i22, thereby imparting gaps 122, 124 and conductor openings 118, 120 - T when viewed from the side Configuration. As shown in Figure 8, in a direction parallel to the transverse axis 116, the gaps 122, 124 extend completely from one edge 1 〇 7 to the other side edge, i.e., the gaps 122, 124 completely cross in the horizontal direction. And extending through the body 1〇2, which extends between the side edges 107 and 1〇8. However, the gaps 122, 124 may extend in a vertical direction, extending between the top surface and the bottom surface ιι, ιι 2 118769.doc -17. 1357608 on only one side of the conductor openings 118, 120, and more specifically, In the illustrative embodiment of FIG. 7, gap 122' 124 may extend between conductor openings 118, 120 and bottom surface 112. It should be noted that the gaps 122, 124 do not extend between the conductor openings ι 18, 12 〇 and the top surface 11 本体 of the body 1 〇 2 . Thus, the gaps 122, 124 do not extend completely between the top and bottom surfaces 110, 112 of the body 102. In particular, the incomplete extension of the gaps 122, 124 is specifically contrasted with a core structure having two core halves that extend between the two core halves as a whole on the two core halves. The gap materials are combined with each other. By integrating the gaps 122, 124 into the single core structure 100 in the case of the unit body 1 2, the plurality of core members can be eliminated, and assembly difficulties and core separation reliability problems of the components in use can be eliminated. Therefore, the material cost and assembly cost are reduced in the case of a single core structure of 1 相比 compared to the conventional core structure. The bottom surface 112 of the body 1〇2 can be formed using an indentation or recessed surface 13〇 defining a land for mounting to a conductor of the core structure 1 (described below). 10 through 12 are similar views of Figs. 7 through 9, except that the conductive member 140 is inserted through the core structure 1 and, more specifically, the conductive member 140 is inserted through the conductor opening 118 of the body ι 2, 12 turns to form the magnetic element 138. The conductive member 140 is shaped to be complementary to the conductor openings 118, ι2 and can be, for example, a generally rectangular and substantially flat strip conductor made of a known conductive material such as, for example, copper or a copper alloy. As best seen in Figure 12, for the entire distance between the side edges 107, 1 〇 8 of the body 102, the conductive features 140 generally extend linearly through the respective conductor openings 、 8, 〇 2 〇, 118769. Doc • 18- /0U8 and the opposite ends 142 of each part 140 are wrapped around the side edges 107, 1 〇 8 and adjacent to the recess 13 形成 formed in the bottom surface 丨 12 of the body 102. The end 142 of the conductive part mo thereby defines a rectangular surface mount type terminal pad 144 on the bottom surface 112 of the body 1〇2. The terminal pads 144 complete the electrical connection through the components when connected to conductive traces (not shown) on the board. The conductive member 140 can be fabricated from a flat sheet of electrically conductive material using a lead frame (not shown) according to known perforation, stamping or forming techniques, and the lead frame can be used to simultaneously insert the electrically conductive member 140 through the body 1〇2 of the core 100. The lead frame can then be trimmed from the conductive part 140 and the end 142 of the part 弯曲4 can be bent or formed into a c-like configuration as shown in FIG. Therefore, the assembly of the conductive parts 140 can be completed in a minimum amount of time using automated processes and machining. Once the conductive features 140 are assembled to the core 1 , each of the conductive features 14 and associated gaps 122, 124 can act as a separate inductor operating on a single core structure. In addition, each of the conductive members 14 is operatively coupled to a different phase of the current, thereby providing a two-phase magnetic structure contained in a single core structure, and a separate inductor element having a separate core structure. The one-piece core structure 100 provides space savings on the board. A surface mount type magnetic component having a one-piece gap core structure 100 is thus provided which achieves benefits similar to the core structures 30 and 5 above. Since the core separation problem is eliminated by using the single core 100, the manufacturing cost can be reduced to provide the core structure 100 and the core structure can be manufactured with increased reliability. Figures 13 through 18 illustrate a fifth embodiment of a gap core structure 2 and a magnetic element 2, wherein similar features of the core structure 100 are indicated by like reference numerals US 769.doc 1357608.

The gap gap core structure 200 is similar to the gap core structure 1〇〇, but the gap core structure 200 has an increased number of conductor turns σ, associated gaps, and conductive parts. That is, the body 2〇2 of the core structure 200 includes four additional conductor openings 2〇4, 2〇6, 2〇8, and 21〇 in addition to the conductor openings ιΐ8 and 12〇. Similarly, in addition to the gaps 122, 124, the body 2"2 includes discrete gaps 212, 214, 216, and 218 formed in a manner and orientation generally similar to the gaps 122 and 124 described above. When the conductive member is inserted through the conductor opening in the body 2〇2 and formed into a braided configuration as seen in Fig. 18, the conductive member 14〇

^ Each of the four (4), 124, 212, 214, 216, and 218 acts as six different surface mount inductor elements integrated into the single core structure 200. Each conductive component 14 can be connected to a conductive trace on the circuit board via a surface mount terminal. The electrical component is operatively connected to six different phases of current and provides substantial space on the circuit board. Xiao Xiao. Core structure 200 additionally provides the same benefits as core structure 100. The salt core structures 100 and 200 are particularly well suited for use in a variety of voltage regulator modules (vrm) that are commonly used in high efficiency, more current applications. However, it should be understood that other applications will benefit from the core structure 1 and 2, and the invention is not considered to be limited to any particular end use or application. One embodiment of a magnetic element is described herein, the magnetic element comprising a unitary core structure made of a magnetic material that is a generally rectangular body. The system is defined by opposing end faces, opposite side edges extending between the end faces, and interconnecting the side edges and the top and bottom surfaces of the end faces. The first conductor opening and each of the end faces and the top and bottom surfaces are 118769.doc 1357608 = and the first conductor opening extends completely through the body and extends across the conductor opening. The room!: The body is not extended, and the first. The conductive path of this port. The first conductive conductor is terminated with ^_in (d) for surface mount type termination, and the conductive member may comprise - ^3 rectangular conductor. The second conductor opening may be formed in the body of the body and spaced apart from the port of the first -T limb, the second in the body and transverse to the second conductor ', 戍 can be established - through the first conductor, etc. Electrical path of the part 1 The first gap extends to the first conductor opening and the first gap and the X-ray body opening can be configured in a τ shape and can be defined by the vertical axis and the horizontal axis, wherein the first conductor is open And the first gap extends substantially parallel to the horizontal axis, and the first gap of the first conductor open disk extends substantially perpendicular to each other. The bottom surface includes opposing recessed surfaces' and the first conductive features can wrap around the opposing and recessed surfaces. The gap is formed without using a spacer member made of a non-magnetic material. An embodiment of a core assembly for surface electronic components is also described herein. The anger assembly comprises: a core comprising a single body of 4 ω u , 匕 3 9 scoops of magnetic material; a plurality of conductors formed in the core, wherein the plurality of conductors Each of the openings is spaced apart from each other; and a plurality of gaps in the entire structure without the use of an insulating spacer material. Each of the gaps is associated with a respective conductor opening in the conductor openings And each of the gaps extends over the body and does not extend completely. One embodiment of a surface mount electronic component is described herein. The component comprises - a single core - the single core comprises - a body uniformly made of magnetic material, 118769.doc • 21 · The body has a longitudinal axis and a horizontal axis. A plurality of conductor openings are formed in the core and extend parallel to the transverse axis. The plurality of conductor openings are spaced apart from each other along the longitudinal axis. a plurality of non-magnetic gaps are physically formed in the core structure adjacent to the respective conductor openings' and the non-magnetic gap is formed without using the insulating material applied to the body. A conductive part is located at the conductor openings Each of the gaps is located adjacent to the conductive fault members, thereby forming a multi-phase electronic component in a single core. Optionally, the core structure comprises two conductors open π. Alternatively, the core structure comprises six conductors An opening may extend only between the conductor openings and one of the side edges. The element may be an inductor. An embodiment of the magnetic element is also described. The element comprises a uniform mass of magnetic material. a single piece core structure having a body having a non-annular line shape having opposite side surface conductor openings σ extending completely between opposite side surfaces and internally located at a spaced apart position from each of the side surfaces Forming the entirety of the interstices into the body m without utilizing the outer gap material applied to the body, the gap having a first end and a second end 'the end end terminating at the first conductor opening and facing A conductor opening is open and the second end extends to the periphery. The component further includes a second conductor opening and a second gap, as desired. The magnetic component is also described herein. The magnetic material monomer is formed as a single core crucible having a body having opposite side surfaces. The first conductor opening extends completely between the opposite side surfaces and is internally located at a spaced apart position from each of the side surfaces. The first gap is formed by using the outer gap material applied to the body to be integrally formed in the body 118769.doc • 22· where the gap has the first - ancient ^ mountain Β β ^, the disciple knows a second end end, the first end end is at the first conductor opening and open to the first conductor opening, and the second end to the periphery. The -c-shaped conductive part extends linearly through the opening, and the wide conductive part has a relative The ends, 35, etc., are wound around the opposite ends to define a surface mount terminal for the component. Optionally, the component further includes a second conductor opening and a second gap, and the component is an inductor. The present invention has been described in terms of a particular embodiment of the invention, but those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claimed invention. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of an exemplary gap core for fabricating a magnetic component. Fig. 2 is a side elevational view of the core structure of the conductor shown in Fig. 1. Fig. 3 is a cross section of the core structure and conductor shown in Fig. 2. Fig. 4 is a cross-sectional view of a portion of Fig. 3 illustrating a magnetic flux line of a core structure. Fig. 5 is a second exemplary embodiment of a gap core structure. Fig. 6 is a third embodiment of an exemplary core structure. Figure 7 is a side elevational view of the fourth embodiment of the gap core structure. Figure 8 is a bottom view of the core of Figure 7. Figure 9 is a cross-sectional view of the core of Figure 8. A side view of the core structure of the conductor is placed. Fig. 12 is a bottom view of the structure shown in Fig. 1. Fig. 12 is a side elevational view of the core structure shown in Fig. 11. Fig. 1 is the fifth of the gap core structure Side view of the embodiment 118769.doc ► 23 - 1357608 Figure 14 is the core of Figure 13 Fig. 15 is a cross-sectional view of the core shown in Fig. 14. Fig. 16 is a side view of the core structure in which the conductor is placed as shown in Fig. 13. Fig. 17 is a bottom view of the structure shown in Fig. 16. 8 is a side elevational view of the core structure shown in Fig. 17. [Main component symbol description]

10 gap magnetic core structure 12 magnetic layer 14 non-magnetic layer 15 magnetic layer peripheral edge / side edge 16 area or opening / conductor opening 17 side surface / inner surface 18 non-magnetic layer peripheral edge 19 top surface 20 conductor part 30 gap core Structure/magnetic core structure 32 Non-magnetic layer or insulating layer 50 Core structure 52 Non-magnetic insulating layer 100 Clearance core structure 102 Rectangular body 104 End face 106 End face 107 Side edge 118769.doc -24 - 1357608 108 Side edge 110 Top surface 112 Bottom surface 114 Vertical axis 116 Horizontal axis 118 Conductor opening 120 Conductor opening 122 Non-magnetic gap 124 Non-magnetic gap 126 End 128 End 130 Indentation or recessed surface/recess 138 Magnetic element 140 Conductive part 142 End 144 Rectangular surface mount terminal pad 200 gap anger structure 201 magnetic element 202 body 204 conductor opening 206 conductor opening 208 conductor opening 210 conductor opening 212 gap · 25 · 118769.doc 1357608 214 gap 216 gap 218 clearance

118769.doc •26

Claims (1)

1357608 Patent application No. 096105754 Patent application for the replacement of the Chinese patent application (September of September) X. Patent application scope: l------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ An early body core structure 'which is made of a magnetic material as a substantially body. The system has opposite end faces, opposite side edges extending between the end faces, and interconnecting the side edges and the end faces. a top surface and a bottom surface are defined; a first conductor opening spaced apart from the end surfaces and the top surface and the bottom surface, the first conductor opening extending completely through the body; the first gap being integrally formed Extending in the body and across the conductor opening, the gap does not extend completely beyond the body; and the first conductive component establishes a conductive circuit through the first conductor opening. The first conductive component is configured Bonded to a surface mount terminal. 2. A magnetic element as claimed in the item, wherein the conductive part comprises a rectangular conductor. 3. The magnetic component as claimed in claim 1, further comprising: a second conductor formed in the body and spaced apart from the first conductor opening; a first gap formed in the body and transverse to the The second conductor opens and extends a second conductive component that establishes an electrical path through the second conductor opening. 4. The magnetic element of claim 4, wherein the first gap extends to the first conductor opening. 5. The magnetic element of claim i, wherein the first gap and the first conductor 1357608 opening are configured in a -τ configuration. |f. </ br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br> Extending the shaft, the first conductor opening and the first gap extend substantially perpendicular to each other. 7. The magnetic component of claim 1, wherein the bottom surface comprises a relatively concave surface&apos; the first conductive component wraps the opposing faces and the concave surfaces. 8. A magnetic component as claimed in claim 1, wherein the conductive member has a shape complementary to the opening. 9. The magnetic component of claim 1 wherein the gap is formed without the use of a spacer member made of a non-magnetic material. 10. A core assembly for a surface electronic component, the core assembly comprising: a core; a monolithic body comprising one of a uniform magnetic material; a plurality of conductor openings formed in the core, the plurality of conductor openings Each of the conductor openings is spaced apart from each other; and a plurality of gaps are integrally formed in the core structure without the use of an insulating spacer material, wherein each of the gaps is in the conductor opening One of the individual conductor openings is associated, and each of the gaps extends beyond the body without extending completely. η. The core assembly of claim 10, further comprising a conductive component in each of the individual conductor openings, 12. The core assembly of claim 1 wherein each of the gaps is substantially perpendicular to The individual conductors extend to extend. 13. The core assembly of claim 1 wherein the conductor openings are substantially moments 118769-1000927.doc 1357608. 14. The core assembly of claim 1 wherein each of the gaps is in communication with the respective conductor openings. 15. The core assembly of claim 1 wherein each of the conductor openings and the associated gaps are configured in a configuration. 16. The core assembly of claim 10, wherein the gaps extend across the conductor openings. 17. A surface mount electronic component comprising: a single core comprising a body uniformly formed from a magnetic material; the body having a longitudinal axis and a transverse axis; a plurality of conductor openings forming Extending in the core and parallel to the transverse axis, the plurality of conductor openings are spaced apart from each other along the longitudinal axis; a plurality of non-magnetic gaps are formed in the core structure adjacent to the respective conductor openings The non-magnetic gaps are formed without using an insulating material applied to the body; and a conductive member is located in each of the conductor openings, the gaps being adjacent to the conductive parts Thereby, one of the single cores of the single core is formed. The electronic component of claim 17, wherein the core structure comprises two conductor openings D 〇 19, such as the electronic component of claim 17, wherein the core structure comprises six conductor openings 〇20. An element, wherein the gaps extend across the respective conductive openings. 118769-1000927.doc 1357608 January ι/|日修φ正正买买 21. The electronic component of claim 17, wherein one of the conductor openings is connected. 22. The electronic component of claim 17, wherein the conductor openings are substantially rectangular. 23. The electronic component of claim 17, wherein the gaps are configured in a configuration with the conductor openings. 24. The electronic component of claim 17, wherein the body is substantially rectangular. 25. The electronic component of claim 17, wherein the gaps extend only between one of the conductor openings and one of the side edges. 26' The electronic component of claim 17, wherein the component is an inductor. 27. A magnetic component comprising: an early core structure uniformly formed of a magnetic material as a body having a non-annular line shape, the body having opposite side surfaces; a first conductor opening entirely in the Extending between opposite side surfaces and internally located at a spaced apart position from one of each of the side surfaces, and a gap that is integral without utilizing external gap material applied to the body Formed in the body, the gap has a first end and a second end that terminates at the first conductor opening and is open to the first conductor opening, and the second end extends to the perimeter. 28. The magnetic component of claim 27, further comprising a second conductor opening and a second gap. 29. The magnetic element of claim 27, further comprising a rectangular conductor inserted through the first conductor opening and wound around the side surfaces. 118769-1000927.doc -4- 1357608 _ January January V|曰修(气)正换页30. — A magnetic element' comprising: a single core structure made of a uniform magnetic material Forming a body having opposite side surfaces; a first conductor opening 'extending entirely between the opposite side surfaces and internally located at a spaced apart position from one of each of the side surfaces; a gap 'which is integrally formed in the body without utilizing an outer gap material applied to the body, the gap having a first end and a second end, the first end terminating at the first conductor opening and Opening the first conductor opening, and the second end extends to the peripheral ridge and a C-shaped conductive member 'linearly extending through the opening, the conductive member having opposite ends, the opposite ends being wound around the side surfaces A surface mount type termination for the component is defined. 31. The magnetic component of claim 30, further comprising a second conductor opening and a second gap. 32. The magnetic component of claim 3, wherein the component is an inductor. 118769-I000927.doc