Magnetic element structure with thermally conductive filler and method of making same

Abstract

A magnetic element structure with a heat conductive filler and a method of manufacturing the same, wherein the magnetic element structure with a heat conductive filler comprises a first magnetic core, a second magnetic core combined with the first magnetic core to form an outer shell with a front opening and a back opening, a coil assembled in the outer shell, wherein two end points of the coil extend from the front opening, and a heat conductive filler filled in the outer shell and between the outer shell and the coil.

Description

[0001] This application is a divisional application of the patent application, No. 202010162749.1, filed on March 10, 2020, for “Magnetic Element Structure with Heat Conductive Filler and Manufacturing Method Thereof”, with the applicant of Qiankun Technology Co., Ltd. TECHNICAL FIELD

[0002] The present disclosure relates generally to a magnetic element structure, and more particularly to a magnetic element structure with heat conductive filler. BACKGROUND

[0003] A magnetic element, such as a transformer or inductor, also known as a reactor, is a two-terminal passive electronic component that resists changes in current flowing through it. It contains a conductor, such as a wire, which is usually wound in a coil shape. When current flows through it, energy is temporarily stored in the magnetic field of the coil. According to Faraday's law of electromagnetic induction, when the current flowing through the conductor changes, an electric field that changes with time is generated in the conductor to oppose such a change in current. Many magnetic elements have a magnetic core made of iron or ferrite, which can be used to enhance the electric field and inductance.

[0004] Magnetic elements are widely used in electronic devices that use alternating current, particularly in radio equipment, power conversion or power isolation applications. For example, inductors are used to block the flow of alternating current and allow direct current to pass through. Inductors designed to achieve this purpose are called chokes. They are also used in electronic filters to separate signals of different frequencies, and together with capacitors to form a tuned circuit.

[0005] The development and popularity of 5G wireless systems and automotive electronics provide great business opportunities for those in the field. The great demand for such passive components in the market has caused a shortage of inductors or transformers. In addition, 5G wireless systems and automotive electronics have more stringent specifications and requirements for the characteristics of magnetic elements. For example, how to more quickly and effectively dissipate the heat generated by the coil and the magnetic core in the magnetic element is an important issue, because the generated heat is more and accumulates, which can increase the temperature of the magnetic element during operation and reduce its efficiency, and eventually or can cause the entire element to burn out. Therefore, the industry still needs to develop new methods and structures to improve the heat dissipation of the magnetic core and coil in the magnetic element. SUMMARY

[0006] To improve the heat dissipation of a magnetic component, the present invention proposes a magnetic component with a heat conductive filler between the coil and the magnetic core to improve the heat conduction therebetween, wherein the unique design of the heat conductive filler not only improves the heat dissipation, but also reduces the manufacturing cost. In addition, the size of the coil and the magnetic core can be reduced accordingly, and the required inductance value is easily achieved, which helps to miniaturize the magnetic component.

[0007] One aspect of the present invention is to provide a magnetic component structure with a heat conductive filler, which comprises a first magnetic core, a second magnetic core combined with the first magnetic core to form an enclosure with a front opening and a rear opening, a coil assembled in the enclosure, wherein two end points of the coil extend from the front opening, and a heat conductive filler filled in the enclosure and between the enclosure and the coil.

[0008] Another aspect of the present invention is to provide a method for manufacturing a magnetic component structure with a heat conductive filler, which comprises providing a mold with a coil assembled therein, casting the mold with a heat conductive material to form a heat conductive filler covering at least a portion of the coil, taking the heat conductive filler and the coil out of the mold, and combining the heat conductive filler with the coil and a magnetic core to form a magnetic component structure.

[0009] These and other objects of the present invention will no doubt become obvious to the reader and it is intended to include all such BRIEF DESCRIPTION OF DRAWINGS

[0010] The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

[0011] Figure 1 is an exploded view of a magnetic component structure according to an embodiment of the present invention;

[0012] Figure 2 is a front perspective view of an assembled magnetic component structure according to an embodiment of the present invention;

[0013] Figure 3 is a rear perspective view of a magnetic component structure according to an embodiment of the present invention;

[0014] Figure 4 is a rear perspective view of a magnetic component structure according to another embodiment of the present invention;

[0015] Figure 5 is a rear perspective view of a magnetic component structure according to yet another embodiment of the present invention;

[0016] Figure 6This is a rear perspective view of a magnetic element structure according to yet another embodiment of the present invention;

[0017] Figure 7 This is a bottom perspective view of a magnetic element structure according to an embodiment of the present invention;

[0018] Figure 8a and Figure 8b A perspective view of the lower magnetic core of the magnetic element structure according to two embodiments of the present invention;

[0019] Figure 9a and Figure 9b for Figure 8a and Figure 8b The top view of the magnetic element structure shown is an offset of the lower core from the middle core.

[0020] Figure 10 This is a perspective view of a magnetic element structure during assembly according to an embodiment of the present invention;

[0021] Figure 11 This is a perspective view of a magnetic element structure during assembly according to another embodiment of the present invention;

[0022] Figure 12 This is a perspective view of a magnetic element structure during assembly according to another embodiment of the present invention;

[0023] Figure 13 A perspective view of a magnetic element structure during assembly according to another embodiment of the present invention; and

[0024] Figure 14a and Figure 14b This is a perspective view of a coil used in a magnetic element structure according to an embodiment of the present invention.

[0025] It should be noted that all illustrations in this specification are for illustrative purposes only. For clarity and ease of illustration, the size and scale of the components in the illustrations may be exaggerated or reduced. Generally, the same reference symbols in the illustrations are used to indicate corresponding or similar component features in modified or different embodiments.

[0026] Explanation of reference numerals in the attached figures:

[0027] 100 Magnetic Component Structure

[0028] 101 Outer Shell

[0029] 101a Front opening

[0030] 101b rear opening

[0031] 110 lower magnetic core

[0032] 111 Central Column

[0033] 113 center leg

[0034] 115 assembly plane

[0035] 120 bobbin

[0036] 120a side wall

[0037] 121 center cylinder

[0038] 130 coil

[0039] 131 terminal

[0040] 140 thermally conductive filler

[0041] 150 insulation paper

[0042] 160 upper core

[0043] 170 elastic tape

[0044] 180 outer cover

[0045] 190 thermally conductive interface material

[0046] C center DETAILED DESCRIPTION

[0047] The present application will be described in detail with reference to the attached drawings, which form a part of this application, and wherein are shown, by way of illustration, specific embodiments by which the application can be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the application, and it is to be understood that other embodiments can be utilized and that structural, logical, and electrical changes can be made without departing from the scope of the present application. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present application is defined by the appended claims and equivalents thereof.

[0048] Reference will now be made to the drawings, in which Figure 1Fig. 1 is a cross-sectional view of a magnetic component structure 100 according to an embodiment of the present application. The magnetic component structure 100 includes a lower magnetic core 110, a bobbin 120, a coil 130, a thermally conductive filler 140, an insulation paper or film 150, and an upper magnetic core 160. The upper magnetic core 160 can be a first magnetic core and the lower magnetic core 110 can be a second magnetic core. The lower magnetic core 110 has a center post 111 extending upward from an assembly plane 115 to allow the bobbin 120 and / or the coil 130 to be assembled thereon. The bobbin 120 can be a bobbin having a shape corresponding to the assembly plane and the inner wall of the lower magnetic core 110, and a hollow center cylinder 121 corresponding to the center post 111 of the lower magnetic core 110 and assembled thereon. The coil 130 is wound and assembled on the center cylinder 121 of the bobbin 120. In the embodiment, the bobbin 120 further includes two side walls 120a extending along the outer side of the coil 130 to improve the insulation between the coil 130 and the upper and lower magnetic cores 160, 110.

[0049] The upper magnetic core 160 has a shape corresponding to the lower magnetic core 110, and after assembly, it combines with the lower magnetic core 110 to enclose all components of the magnetic component structure 100. The thermally conductive filler 140 is filled in a portion or the entire remaining space between the upper magnetic core 160 and the lower magnetic core 110. The insulation paper 150 is disposed between the thermally conductive filler 140 and the upper magnetic core 160 to provide better insulation properties. In addition, an elastic tape 170 can be attached to the back of the magnetic component structure 100 to seal the back opening formed by the combination of the upper magnetic core 160 and the lower magnetic core 110. It should be noted that the arrangement and configuration described above are only a preferred embodiment of the present application, and in actual implementation, some components such as the bobbin 120, the insulation paper 150, and / or the elastic tape 170 can not be used, or these components can be replaced by other components. In addition, other embodiment variants can modify existing components or add other components. Furthermore, the front opening and the back opening formed after assembly are opposite to each other in two parallel and opposite directions of the expansion stress. These openings function to release the expansion stress generated by heat during operation, which can greatly reduce the stress borne by the upper and lower magnetic cores 160, 110. The thermal conductivity of the thermally conductive filler 140 and the thermally conductive interface material is greater than about 0.3 watts per meter-kelvin (W / mk). According to other embodiments of the present application, the thermally conductive interface material does not cover the outer surfaces of the upper magnetic core 160 and the lower magnetic core 110.

[0050] In the present application, the material of the upper magnetic core 160 and the lower magnetic core 110 can be a powder core with low permeability, such as ferrosilicon alloy and ferronickel alloy, or a ferrite with higher permeability. The material of the insulation paper / film 150 can be DuPont Nomex fiber or Kapton film, with a thickness sufficient to achieve the electrical insulation requirement and an area larger than the top surface of the energized coil 130. The material of the bobbin 120 can be plastic, such as engineering plastic, which can withstand the tension of the coil winding. The material of the thermally conductive filler 140 (thermal conductivity greater than 0.3 W / mk) can be inorganic material with good thermal conductivity, such as epoxy resin, silica gel, polyurethane (PU), or thermosetting phenolic resin, thermoplastic polyethylene terephthalate (PET), polyamide (PA), polyphenylene sulfide (PPS), and polyether ether ketone (PEEK) with thermal conductivity greater than 0.3 W / mk.

[0051] Next, please refer to Figure 2 , which is a front perspective view of the assembled magnetic component structure 100 according to an embodiment of the present application. In this embodiment, the lower magnetic core 110 and the upper magnetic core 160 are combined to form a housing 101, which contains all the components of the magnetic component structure 100, and also forms a front opening 101a for the terminals 131 of the coil 130 to extend out of the front of the housing 101. The bobbin 120 is assembled along the inner wall of the housing 101, and the thermally conductive filler 140 fills at least part or the entire remaining space inside the housing 101 and covers at least part or the entire coil 130 (excluding its two terminals 131) and the bobbin 120. The insulation paper 150 is arranged between the shaped thermally conductive filler 140 and the upper magnetic core 160.

[0052] In operation, the heat generated by the coil 130 is first conducted to the thermally conductive filler 140 surrounding it. The thermally conductive filler 140 with excellent thermal conductivity can effectively conduct heat from the coil 130 to the surrounding housing 101, and the insulation paper 150 between them can facilitate this conduction. The upper magnetic core 160 and the lower magnetic core 110 themselves are also good thermal conductors, which can further conduct heat to the external heat dissipation structure on which the magnetic component structure 100 is mounted, such as the cooling plate of a mobile phone or a vehicle.

[0053] In an embodiment, the thermally conductive filler 140 is formed by pouring a thermally conductive material into a mold composed of the upper magnetic core 160 and the lower magnetic core 110, which will entirely or partially cover the coil 130 assembled inside it.

[0054] Next, please refer to Figure 3This is a rear perspective view of the magnetic element structure 100 according to an embodiment of the present invention. The rear opening (not shown) formed by the combination of the lower magnetic core 110 and the upper magnetic core 160 can be covered by an outer cover 180. In this embodiment, the outer cover 180 is part of the outer casing 101 and can be glued to the rear of the upper magnetic core 160 and the lower magnetic core 110 in a manner flush with the shape of the outer casing 101. The outer cover 180 structure is added to the magnetic element structure 100 to seal the rear opening of the outer casing 101, so that the thermally conductive filler is retained in the internal closed space during the potting process until it cures.

[0055] Next, please refer to Figure 4 This is a rear perspective view of a magnetic element structure 100 according to another embodiment of the present invention. In this embodiment, the rear opening 101b of the housing 101 does not resemble... Figure 3 Similarly, it is concealed by the outer cover, allowing the thermally conductive filler 140 to extend outward from the internal space of the housing 101. This design is suitable for magnetic component structures where part of the coil extends beyond the rear of the housing 101. Even if it extends beyond the rear of the housing 101, the protruding thermally conductive filler 140 can completely cover such coils. In manufacturing, this protruding filler structure can be achieved by using the upper magnetic core 160 and the lower magnetic core 110 as a mold during the casting of the thermally conductive filler material, and a similar... Figure 3 The outer cover 180 is formed by an additional module (not shown) behind it. This additional module provides internal molding space to form the protruding portion of the thermally conductive filler 140. After the thermally conductive filler 140 has cured, this additional module can be removed from the magnetic cores 110, 160 and the thermally conductive filler 140. If there is contact with an external cooling structure, this protruding thermally conductive structure can also provide better heat dissipation.

[0056] Next, please refer to Figure 5 This is a rear perspective view of a magnetic element structure according to another embodiment of the present invention. This embodiment is not like... Figure 3 Instead of using an outer cover 180 to block the rear opening of the housing 101, an adhesive elastic tape 170 is attached to the rear of the housing 101 to seal the rear opening. The advantage of this design is that it provides flexible space and tolerance for the thermally conductive filler formed within the housing 101. In actual manufacturing, the cured thermally conductive filler will exert considerable stress on the assembled magnetic cores 110, 160; without sufficient space for expansion, this could even cause the cores to crack. The attached elastic tape 170 can act as a bottom cover during casting to hold the thermally conductive filler material inside, and if necessary, it can also be squeezed out by the cured and expanded thermally conductive filler to provide space for outward extension. Without expansion, the surface of the thermally conductive filler will be flush with the rear opening of the housing 101.

[0057] Next, please refer toFigure 6 This is a rear perspective view of a magnetic element structure 100 according to another embodiment of the present invention. In another variation of the invention, the thermally conductive filler 140 in the magnetic element structure 100 may be in a semi-filled or partially filled form. Figure 6 As shown, the thermally conductive filler 140 partially fills the space from the lower core 110 towards the upper core 160. The partially filled thermally conductive filler 140 will behave like... Figure 4 It extends from the rear opening 101b of the outer casing 101, just like before. Figure 6 As can be seen, some of the winding frame 120 and coil 130 are exposed from the thermally conductive filler 140 in the unfilled space. This means that in this embodiment, the thermally conductive filler 140 does not completely cover the internal components. The advantage of this semi-filled or partially filled form is that it can save considerable material costs and reduce the expansion stress caused by thermal energy during operation. Because almost half the amount of thermally conductive filler 140 is used in this process, and because there is still sufficient thermal conductivity contact area between the thermally conductive filler 140 and the lower magnetic core 110, it can maintain appropriate thermal conductivity properties. In manufacturing, this semi-filled and extended structure can be formed by laterally casting and curing the thermally conductive filler 140. The outer shell 101 requires auxiliary molds at the front and rear to maintain the cured thermally conductive filler material until it is cured into the thermally conductive filler 140.

[0058] Next, please refer to Figure 7 This is a bottom and inner perspective view of a magnetic element structure 100 according to an embodiment of the present invention. Figure 6 Similar to the previous embodiment, the thermally conductive filler 140 in this embodiment is also in a partially or fully filled form. However, in this embodiment, the thermally conductive filler 140 is formed by upright casting, and the rear opening 101b of its outer shell 101 is blocked by elastic tape or the outer shell. The thermally conductive filler 140 partially fills the outer shell 101 from the rear opening 101b towards the front opening 101a. Figure 6 Compared to the previous embodiment, the contact area between the thermally conductive filler 140 and the lower magnetic core 110 in this embodiment is much smaller. Despite the compromise in thermal conductivity, the advantage of this design lies in its simple upright casting process. The cast, uncured thermally conductive filler 140 can be easily maintained within the shell without the aid of auxiliary molds. The outer surfaces of the upper and lower magnetic cores 160, 110 corresponding to the thermally conductive filler 140 will serve as heat dissipation surfaces, contacting the heat sink.

[0059] Next, please refer to Figure 8a and Figure 8b This is a perspective view of the lower magnetic core 110 of the magnetic element structure according to two embodiments of the present invention. The magnetic element structure of the present invention can employ various types of lower magnetic cores 110, such as... Figure 8athe EQ core or Figure 8b the E core. The EQ lower core 110 has a center post 111 for coil or bobbin assembly. Unlike the former, the E lower core 110 has a center bar 113 for coil winding. Both types of lower core 110 have the front opening 101a and the back opening 101b for internal components to protrude out. Note that the lower core 110 types described above are only used as examples. Other types of lower core 110, such as EP core, ER core, ETD core, PM core, and PQ core, can be used in the present invention to assemble with the upper core 160 of the same core type, or simply use the I core directly.

[0060] Next, refer to Figure 9a and Figure 9b which are Figure 8a and Figure 8b the top view of the lower core 110 of the magnetic component structure shown above, offset from the center. As shown in the figure, the center post 111 and the center bar 113 of the lower core 110 in both examples are offset from the assembly plane 115 of the lower core 110 towards the front opening 101a from the center C. The purpose of this design is to avoid the coil assembled on these center posts 111 or center bars 113 from protruding out of the back of the lower core 110. In this way, the coil wound on the post or bar can also be offset towards the front opening 101a, and thus the back opening 101b can be sealed with the elastic tape, which can be easily removed after casting, providing better process flexibility. The molded thermally conductive filler 140 in both examples can be flush with the back opening 101b, instead of protruding out as in Figure 4 the conventional design.

[0061] After the above various examples are described, now refer to Figures 10-13 which shows the assembly of a magnetic component structure according to various embodiments of the present invention. The thermally conductive filler 140 of the present invention can be molded in different forms. First, refer to Figure 10 In this example, the thermally conductive filler 140 is formed to partially cover the coil 130 and almost completely cover the entire lower core 110. In the process, the thermally conductive filler material is injected into a mold (not shown) containing the lower core 110 and the coil 130 thereon. The injected thermally conductive filler material is cured to form the thermally conductive filler 140, which covers the lower half of the lower core 110 and the coil 130. After being removed from the mold, the lower core 110 with the coil 130 covered is assembled with the upper core 160 to form the magnetic component structure. The benefit of this design is that the process is quite simple, and compared to those examples in which the lower core 110 is not covered, the complete coverage of the thermally conductive filler 140 can provide better heat dissipation efficiency and lower thermal expansion stress for the magnetic component structure.

[0062] Next, please refer to Figure 11 In this embodiment, the thermally conductive filler 140 can also be formed together with the lower magnetic core 110 in another form. For example... Figure 11 As shown, the thermally conductive filler 140 is formed on the assembly plane 115 of the lower magnetic core 110, and its shape follows the inner wall of the lower magnetic core 110 and is at least partially or entirely flush with its rear surface. In this embodiment, the thermally conductive filler 140 can be formed by pouring thermally conductive filler material into a mold having a predetermined shape and sidewall profile, which consists of the lower magnetic core 110 and an upper mold (not shown). After the thermally conductive filler 140 is cured and removed from the upper mold, the thermally conductive filler 140, which internally covers part or all of the lower magnetic core 110 and the coil 130, can be assembled and joined with the upper magnetic core 160 to form a magnetic element structure. Similarly, the advantage of this design is that its process is quite simple, and the thermally conductive filler 140 can be formed together with the lower magnetic core 110 to avoid tolerances between the formed thermally conductive filler 140 and the magnetic core during assembly, especially for ferrite cores that are sintered and whose dimensions are not expected to shrink.

[0063] Next, please refer to Figure 12 .and Figure 10 Similarly, in this embodiment, the thermally conductive filler 140 is formed together with the lower magnetic core 110. However, in this embodiment, the winding frame 120 is included in the molding of the thermally conductive filler 140. During manufacturing, the coil 130 is first wound onto the winding frame 120, and the winding frame 120 is further assembled onto the lower magnetic core 110. After these three components are assembled, the entire assembly is placed into a mold (not shown) with a specific shape and inner contour for casting. The coil 130 can be completely or partially covered by the thermally conductive filler 140 above the winding frame 120 and the lower magnetic core 110, with only the top of the winding frame 120 exposed. After demolding, the lower magnetic core 110, along with the covered thermally conductive filler 140, the winding frame 120, and the coil 130 assembled thereon, is assembled and joined with the upper magnetic core 160 to form a magnetic element structure. The advantage of this design is that it incorporates the winding frame 120 into the molding of the thermally conductive filler 140, making it suitable for more complex designs, such as more complex coil structures or complex internal assemblies. Furthermore, an elastic thermally conductive interface material 190 can be optionally placed between the thermally conductive filler 140 and the upper magnetic core 160, or between the thermally conductive filler 140 and the lower magnetic core 110. This material can absorb the stress generated by the thermally conductive filler 140, fill any gaps between the winding frame 120 and the upper magnetic core 160, and provide better insulation and thermal conductivity. The elastic thermally conductive interface material 190 can be a thermally conductive adhesive, thermal paste, heat sink, or thermally conductive gap material, etc., with a hardness lower than that of the thermally conductive filler 140 and / or the upper and lower magnetic cores 160, 110, to further reduce thermal stress and assembly tolerances.

[0064] Next, refer to Figure 13 Unlike the embodiment of Figure 12 , the heat conductive filler 140 in this embodiment is not formed together with the lower magnetic core 110. Instead, it is formed separately using a mold (not shown) having an inner contour corresponding to one of the magnetic cores 110, 160. After solidification, the heat conductive filler 140 will cover the coil 130 and can be conformally assembled between the lower magnetic core 110 and the upper magnetic core 160 to form the magnetic component structure. Similarly, an elastic heat conductive interface material 190 can be provided between the heat conductive filler 140 and the upper magnetic core 160 or between the heat conductive filler 140 and the lower magnetic core 110, which can absorb the stress generated by the magnetic cores, fill the possible gap between the heat conductive filler 140 and the upper magnetic core 160, and provide better insulation and heat conduction properties. The advantage of this embodiment is that it provides a better elastic design for assembly, because its heat conductive filler 140, magnetic core 110, 160 is formed individually and can be assembled at the appropriate time.

[0065] Finally, refer to Figure 14a and Figure 14b , which are perspective views of two types of coils 130 used in the magnetic component structure according to embodiments of the present application. Figure 14a shows a round wire type coil 130, Figure 14b shows a copper sheet type coil. Please note that the coil 130 types described above are only used as an example, and other types of coils, such as flat wire, multi-strand wire, multi-strand self-adhesive wire, or combinations thereof, can be used in the present application. If the coil is in the form of flat wire, copper sheet, or thick round wire, such coils can be molded with the heat conductive filler 140 without using a bobbin. If the coil is in the form of round wire, multi-strand wire, or composite wire, such coils are fixed using a bobbin during the casting process to make their position less likely to shift and their shape less likely to deform, as shown in Figure 12 .

[0066] In the present application, the method of casting and solidifying heat conductive filler material between the coil and the magnetic core to form a heat conductive filler can greatly improve the heat dissipation efficiency of the magnetic component structure, so that the coil diameter, the magnetic core volume, and the overall magnetic circuit can be further reduced to increase the inductance value. This design can achieve the desired inductance value on the basis of fewer coils and smaller magnetic cores, and the magnetic component structure has advantages in electrical properties and manufacturing cost.

[0067] The above only describes the preferred embodiments of the present application, and any equivalent changes and modifications made in accordance with the claims of the present application shall be within the scope of the present application.

Claims

1. A method for making a magnetic component structure with a thermally conductive filler, comprising: providing a mold with a coil, the mold comprising an upper mold member and a second magnetic core; casting the mold with a thermally conductive material to form a thermally conductive filler covering at least a portion of the coil; removing the thermally conductive filler and the coil from the upper mold member; and combining the thermally conductive filler with the coil and a magnetic core to form a magnetic component structure, wherein the thermally conductive filler with the coil and a first magnetic core form at least a front opening and at least a back opening, the front opening and the back opening being oppositely disposed on two sides of the first magnetic core and the second magnetic core, such that the thermally conductive material is exposed at the front opening and the back opening; and the thermally conductive filler is at least partially received between the first magnetic core and the second magnetic core.

2. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, wherein the thermally conductive material does not cover the first magnetic core.

3. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, wherein the step of casting the mold with the thermally conductive material comprises shaping the thermally conductive filler within the second magnetic core to follow an inner wall of the second magnetic core.

4. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, wherein the step of casting the mold with the thermally conductive material comprises shaping the thermally conductive filler covering at least a portion of the coil to extend upward from an assembly plane of the second magnetic core into a winding space of the first magnetic core, such that the shape of the thermally conductive filler is inwardly recessed with respect to an outer shape of the first magnetic core and is receivable in the winding space of the first magnetic core.

5. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, wherein the step of casting the mold with the thermally conductive material comprises shaping the thermally conductive filler to cover at least a portion of an outer surface of the second magnetic core.

6. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, wherein the step of casting the mold with the thermally conductive material comprises shaping the thermally conductive filler to not cover the second magnetic core and an assembly plane of the first magnetic core.

7. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, further comprising a bobbin assembled on the second magnetic core, the coil being wound on the bobbin, and at least a portion of the coil being covered by the thermally conductive filler on the bobbin and the second magnetic core.

8. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 7, wherein the bobbin further comprises two side walls, the outer shape of the side walls extending along the outer side of the coil.

9. The method for making a magnetic component structure with a thermally conductive filler as claimed in claim 1, further comprising a thermally conductive interface material between the magnetic core and the thermally conductive filler, wherein the hardness of the thermally conductive interface material is less than the hardness of the thermally conductive filler and the magnetic core.

10. A method for making a magnetic component structure with a thermally conductive filler, comprising: and A mold is provided, which is composed of a first magnetic core and a second magnetic core, and a coil is assembled in the mold, wherein the first magnetic core and the second magnetic core combine to form at least one front opening and at least one rear opening, the front opening and the rear opening are oppositely arranged on both sides of the first magnetic core and the second magnetic core; and a sealing assembly is temporarily arranged in all the rear openings to seal the rear openings, so as to form a closed space between the first magnetic core, the second magnetic core and the sealing assembly, and the coil is assembled in the closed space; ​ casting the mold with a thermally conductive material to form a thermally conductive filler that encloses at least a portion of the coil, wherein the thermally conductive material is cast from the front opening into the enclosed space between the first magnetic core, the second magnetic core, and the closure assembly such that the thermally conductive material encloses at least a portion of the coil; removing the closure assembly after the thermally conductive material is cured such that the thermally conductive material is exposed at the front opening and the back opening.

11. The method of claim 10, wherein the step of casting the mold with the thermally conductive material comprises shaping the thermally conductive filler within the first magnetic core and the second magnetic core to follow the inner walls of the first magnetic core and the second magnetic core.

12. The method of claim 10, wherein the step of casting the mold with the thermally conductive material comprises extending the thermally conductive material outward from an opening of the first magnetic core and the second magnetic core.

13. The method of claim 10, further comprising a bobbin assembly between the first magnetic core and the second magnetic core, the coil being wound around the bobbin, and at least a portion of the coil being enclosed by the thermally conductive filler on the bobbin and the second magnetic core.

14. The method of claim 13, wherein the bobbin further comprises two side walls shaped to extend along the outside of the coil.

15. The method of claim 10, wherein the step of casting the mold with the thermally conductive material comprises casting an underfilled thermally conductive filler from the front opening.

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