Magnetic components with edge field shielding

Abstract

The present invention relates to a magnetic component comprising: at least one magnetic core, wherein at least one gap is formed between end faces, particularly opposing end faces, of the magnetic core; at least one electrical winding surrounding at least a portion of the at least one magnetic core; and a shielding device for shielding the edge field of the at least one gap. The shielding device comprises: a retaining unit attached to the at least one magnetic core and / or the at least one electrical winding at the periphery of the at least one gap; and at least one shielding member attached to the retaining unit; wherein the at least one shielding member is configured to shield the edge field of the gap at the periphery of the gap.

Description

Technical Field

[0001] This invention relates to a magnetic component having an edge field shielding device. Background Technology

[0002] For example, conventional magnetic components used in power converters include one or more magnetic cores and one or more electrical windings. Air gaps, either within or between these cores, are used to control inductance or increase the saturation current of the magnetic components. It is known that air gaps in the cores cause air gap edge fields, which can induce alternating current (AC) losses or heat generation in adjacent components, especially at high frequencies. Furthermore, edge fields can significantly affect the electromagnetic interference (EMI) behavior of magnetic components and devices containing them. These air gaps are typically surrounded by copper windings, which act as shielding against the magnetic edge fields generated at the periphery of the air gaps. However, these edge fields cause high alternating current (AC) losses, especially at high frequencies. To mitigate this, expensive Litz wire (enameled stranded wire) is typically used to reduce AC copper losses. Another way to reduce AC losses caused by air gaps is to move the windings away from the air gaps. However, this method results in high direct current (DC) losses and increased component size. Another way to reduce winding AC losses is to provide copper windings that do not surround the air gaps. However, a drawback of this method is that the air gap edge field is not shielded by the copper winding. Furthermore, keeping magnetic components with unshielded air gaps away from adjacent components to reduce AC losses or heat generation in those components results in lower device power density, which is also disadvantageous. This separation also increases the thermal resistance of the rack holding the magnetic components, potentially leading to further increases in device temperature.

[0003] CN 108257768 A discloses a stray flux shielding structure for a differential common-mode integrated inductor. In this structure, a core portion is formed to include a demagnetizing shielding portion surrounding an air gap, which is created by connecting this core portion to an E-shaped core portion. However, a drawback of this method is that the core portion of this magnetic component must be completely redesigned to provide this integrated demagnetizing shield. Furthermore, especially since the bulk magnetic shielding structure described herein is made of the same material as its core portion, magnetic short circuits via the bulk magnetic shielding structure are highly possible, leading to power losses and undesirable heat generation.

[0004] JP 4279647 B2 discloses a magnetic field shielding mechanism for an electromagnet. In this mechanism, a pair of shielding members are disposed on either side of an air gap to sandwich the air gap in the middle. However, the shielding members are formed of a non-magnetic material with electrical conductivity. Therefore, the shielding members described herein are unsuitable for shielding the magnetic edge field of the air gap. Furthermore, the eddy currents generated in these shielding members significantly increase the heating of this magnetic component. Moreover, the complexity of providing such shielding members necessitates a redesign of the magnetic component, particularly the placement of the electrical windings. Summary of the Invention

[0005] The purpose of this invention is to provide a magnetic component with a shielding device that can shield the edge field of the gap formed between one or more magnetic cores, and can be easily applied without requiring a complex redesign of the magnetic component.

[0006] This objective is achieved by the features of the independent claims. The dependent claims contain advantageous embodiments of the invention.

[0007] This invention relates to a magnetic component comprising at least one magnetic core and at least one electrical winding, the at least one electrical winding surrounding at least a portion of the at least one magnetic core. At least one gap is formed between the end faces of one or more magnetic cores, particularly between opposing end faces. The magnetic component further includes a shielding device for shielding the edge field of the at least one gap. The shielding device includes a retaining unit attached to at least one magnetic core and / or at least one electrical winding at the periphery of the at least one gap; preferably, the retaining unit is attached only to at least one magnetic core. Furthermore, the shielding device includes at least one shielding member attached to the retaining unit, wherein the at least one shielding member is configured to shield the gap edge field at the periphery of the gap.

[0008] The retaining unit is preferably not manufactured integrally with the magnetic core, but is a separate component attached to at least one magnetic core and / or at least one electrical winding. For example, the retaining unit is clamped and / or glued to at least one magnetic core and / or at least one electrical winding.

[0009] The retaining unit is preferably a single piece, such as one that is injection molded.

[0010] The shielding member is preferably made of a material different from that of the retaining unit. The shielding member is preferably a separate element attached to the retaining unit. For example, the shielding member is clamped and / or glued to the retaining unit, or the shielding member is overmolded (injection molding) by the retaining unit.

[0011] Preferably, one to ten, more preferably one to four, shielding members are attached to a single retaining unit. The single shielding member is preferably a plate-shaped element.

[0012] Preferably, the shielding member is located outside the retaining unit, such that the retaining unit is located between the shielding member and the magnetic core.

[0013] The advantage of the magnetic component of the present invention is that the edge field of at least one gap can be shielded by at least one shielding member. Furthermore, the retaining unit for at least one shielding member provides a simple way to position at least one shielding member at the periphery of at least one gap.

[0014] Preferably, the retaining unit includes at least one side surface configured to at least partially surround the gap and retain at least one shielding member. This has the advantage that the shielding device can be easily assembled and that at least one shielding member can be reliably retained by the retaining unit.

[0015] Preferably, the magnetic core is partially or completely surrounded in the circumferential direction by the side surfaces of the retaining unit. Preferably, the retaining unit comprises three or four side surfaces.

[0016] Preferably, the retaining unit is attached between the end faces of the magnetic cores. In other words, the retaining unit is preferably attached between the end faces of one or more magnetic cores. This has the advantage that the retaining unit can be easily attached to the periphery of at least one gap. Furthermore, the retaining unit can thus be suitably attached to magnetic cores of various designs.

[0017] Advantageously, in order to attach the retaining unit between the end faces, the retaining unit includes a receiving portion configured to receive one of the end faces. The receiving portion may particularly be disposed between multiple side surfaces of the retaining unit. Preferably, the receiving portion is formed by an internal space defined by multiple, preferably three or four side surfaces. Preferably, the side surfaces of the retaining unit rest on multiple portions of the outer surface of the magnetic core; wherein these portions of the outer surface are directly adjacent to the end faces.

[0018] Preferably, the retaining unit includes an additional receiving portion, which is located, in particular, between a plurality of side surfaces of the retaining unit and is configured to receive opposing end faces. Preferably, the additional receiving portion is formed by an internal space defined by a plurality of, preferably three or four, side surfaces. Preferably, the side surfaces of the retaining unit rest on a plurality of portions of the outer surface of the magnetic core; wherein these portions of the outer surface are directly adjacent to the end faces.

[0019] In other words, the retaining unit may include a single receiving portion configured to receive one of the receiving end faces. Preferably, the retaining unit may include an additional receiving portion configured to receive an end face opposite to one received by another receiving portion. Thus, the retaining unit has the advantage of being easily and reliably attached between the end faces of the magnetic core.

[0020] Preferably, each side surface of the unit extends beyond the gap and the two end faces, such that each side surface can form part of two receiving portions.

[0021] In another embodiment, the retaining unit is attached only to the outer surface of the magnetic core, and not to the end face of the magnetic core. Preferably, such a retaining unit is used at the intermediate gap of the EE structure. In other words, the retaining unit includes two opposing side surfaces (excluding the receiving portion) that surround the magnetic core. Preferably, the retaining unit is attached to the outer surface of one magnetic core, or to an outer surface formed by the outer surfaces of multiple magnetic cores. This has the advantage that the retaining unit can be attached to the magnetic core regardless of its design. Furthermore, the retaining unit can thus be used as a spacer to separate electrical windings from each other.

[0022] Preferably, the retaining unit snaps onto the outer surface of at least one magnetic core. This has the advantage that the retaining unit can be easily and reliably attached to the magnetic core, especially regardless of the design of the magnetic core and the placement of at least one electrical winding surrounding the magnetic core. It is also preferable that the retaining unit snaps onto the outer surface of at least one electrical winding.

[0023] Preferably, the retaining unit includes at least one spacer portion that protrudes into the gap, and separates at least two opposing end faces with respect to the spacer portion. More preferably, at least one spacer portion protrudes into the gap from at least one side surface of the retaining unit. Thus, the retaining unit can separate at least two opposing end faces of the magnetic core.

[0024] Preferably, the spacer portion is frame-shaped. An air gap is defined in the gap between the end faces through the opening of the frame-shaped spacer portion. Preferably, the frame-shaped spacer portion is annular or rectangular. In other words, the spacer portion preferably has an opening, particularly at its center, which defines an air gap in the gap between the opposing end faces of the magnetic core. This has the advantage that the retaining unit has almost no effect on the inductance of the magnetic core compared to the case where the gap between the end faces of the magnetic core is an air gap.

[0025] In another advantageous embodiment, the spacer portion fills the gap between the end faces. This has the advantage that the physical properties of the gap can be adjusted by the size and / or material composition of the spacer portion.

[0026] Preferably, the retaining unit includes at least one shielding member spacer that protrudes from a side surface of the retaining unit to separate the two shielding members. This at least one shielding member spacer protrudes from the respective side surface, particularly in a direction away from or opposite to the magnetic core. Specifically, the shielding member spacer may protrude perpendicularly to the respective side surface of the retaining unit. This has the advantage that a magnetic short circuit between the two shielding members can be prevented by the shielding member spacer. Furthermore, the physical characteristics of the shielding device, such as its effect on the inductance of the magnetic core, can be adjusted by changing the size, number, and / or material composition of the shielding member spacers.

[0027] Preferably, the shortest distance between the shielding member and the nearest edge of the corresponding gap is defined as L, and the width of the corresponding gap is defined as D, where L > D. In other words, the shortest distance between the shielding member and the nearest edge of the corresponding gap is greater than the width of the corresponding gap. This has the advantage of reliably and advantageously preventing magnetic short circuits in magnetic components.

[0028] Preferably, the quotient of L / D is between a maximum value and a minimum value, including both. The maximum value is preferably 5, more preferably 3, and even more preferably 2. Alternatively, the minimum value is preferably 1.1, more preferably 1.2, even more preferably 1.3, even more preferably 1.4, and even more preferably 1.5. Alternatively, the quotient of L / D is one of the above values. This range and value have the advantage of preventing magnetic short circuits in magnetic components.

[0029] In an advantageous embodiment, the shielding member overlaps with at least one end face. Preferably, the shielding member overlaps with at least one end face when viewed from a direction in a plane parallel to the at least one end face. Preferably, the shielding member overlaps with only one, two, or all of the opposing end faces of the magnetic core. In other words, when the shielding member overlaps with two opposing end faces, the length of the shielding member in the direction spanning the respective gap is greater than the aforementioned width D. This has the advantage of enabling the shielding member to reliably shield the gap edge field at the periphery of the gap.

[0030] Preferably, at least one shielding member is a ferrite plate. This has the advantage that the shielding member can reliably shield the gap edge field at the periphery of the gap without increasing the possibility of electrical short circuits in the magnetic components or the possibility of eddy currents being generated in the shielding member.

[0031] Advantageously, the retaining unit is an electrical insulator. Preferably, the retaining unit comprises or is composed of plastic or ceramic materials. This has the advantage that the retaining unit does not conduct or generate eddy currents, and therefore does not generate additional heat.

[0032] In a further advantageous embodiment, at least one electrical winding does not surround at least one gap. In particular, it is preferred that at least one electrical winding does not even partially surround the gap. This has the advantage that at least one electrical winding can be placed on the magnetic core for desired AC loss reduction, while the shielding device provides shielding against the edge field of at least one gap.

[0033] Preferably, at least one core plate is attached to the retaining unit. The retaining unit thus positions at least one core plate within a gap for air gap distribution. Large air gaps can be distributed into smaller air gaps to reduce the amplitude of stray fields in the air gap region. This reduces eddy current losses in adjacent windings and minimizes electromagnetic interference in the device.

[0034] The core plate is preferably formed of a ferrite material. Therefore, the core plate can be magnetized, but is preferably non-conductive, i.e., electrically insulating. Here, the core plate may comprise hard ferrite materials and / or soft ferrite materials, or may be composed entirely of hard ferrite materials and / or soft ferrite materials. In particular, the core plate is a ferrite plate, i.e., formed of ferrite material and plate-shaped.

[0035] The core plate is specifically perpendicular to the shielding member with the same gap as the shield. Preferably, the retaining unit separates at least one core plate from the two opposite end faces of the magnetic core.

[0036] Preferably, more than one core board, preferably two, three, four, or five core boards, are attached to a single retaining unit and positioned in the same gap. Thus, the retaining unit separates the core boards from each other, for example, by a partition wall.

[0037] Preferably, the retaining unit has an insertion portion for each core board. The insertion portion is preferably a sliding groove for sliding the core board.

[0038] Furthermore, the retaining unit is a single component that retains the shielding member and, more preferably, the core plate.

[0039] The present invention also relates to a power converter, particularly a switch-mode power converter, comprising at least one magnetic component as claimed or described herein. Attached Figure Description

[0040] Further details, advantages, and features of preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Wherein:

[0041] Figure 1a and Figure 1b A schematic diagram of a magnetic component in a pre-assembled state and a post-assembled state according to a first embodiment of the present invention is shown.

[0042] Figure 2a and Figure 2bA schematic diagram of a magnetic component in a pre-assembled state and a post-assembled state according to a second embodiment of the present invention is shown.

[0043] Figure 3a and Figure 3b A schematic diagram of a magnetic component in a pre-assembled state and a post-assembled state according to a third embodiment of the present invention is shown.

[0044] Figure 4a and Figure 4b A schematic diagram of a magnetic component in a pre-assembled state and a post-assembled state according to a fourth embodiment of the present invention is shown.

[0045] Figure 5a and Figure 5b A schematic diagram of a magnetic component in a pre-assembled state and a post-assembled state according to a fifth embodiment of the present invention is shown.

[0046] Figure 6a and Figure 6b A schematic diagram of a magnetic component in a pre-assembled state and a post-assembled state according to a sixth embodiment of the present invention is shown.

[0047] Figures 7a to 7d A schematic diagram of a shielding device for a magnetic component according to the foregoing embodiment of the present invention is shown;

[0048] Figure 8 A cross-sectional view of a magnetic component according to the foregoing embodiment of the present invention is shown;

[0049] Figure 9 A schematic diagram of a pre-assembled magnetic component with a core plate for air gap distribution is shown for all embodiments; and

[0050] Figure 10 A schematic diagram of a shielding device with a core plate for air gap distribution is shown for use in all embodiments.

[0051] Figure label:

[0052] 1-Magnetic component; 2-Magnetic core; 3-Gap; 4-End face; 5-Electrical winding; 6-Outer surface; 7-Leg; 10-Shielding device; 11-Holding unit; 12-Shielding member; 13-Side surface; 14-Receiving part; 15-Gap part; 16-Opening; 17-Shielding member spacer; 18-Slot; 19-Nearest edge; 20-Core plate; 21-Plug-in part; and 22-Separation wall. Detailed Implementation

[0053] In the following description and figures, features and elements that are similar or identical in function have the same reference numerals, and repeated descriptions of them may be omitted.

[0054] Figure 1a and Figure 1b Schematic diagrams are shown of the magnetic component 1 in a pre-assembled state and a post-assembled state according to a first embodiment of the present invention. Specifically, Figure 1a The magnetic component 1 is shown in a pre-assembled state, while Figure 1b The magnetic component 1 is shown in its assembled state. Furthermore, Figures 7a to 7d Each of the above shows a schematic diagram of the shielding device 10 of the magnetic component 1 according to an embodiment of the magnetic component 1.

[0055] In this embodiment, the magnetic component 1 includes two U-shaped magnetic cores 2, commonly referred to as a "UU configuration". Furthermore, the magnetic component 1 includes two electrical windings 5, each winding surrounding one of the magnetic cores 2. Each U-shaped magnetic core 2 includes two legs 7. The electrical windings 5 ​​are disposed between the two legs 7 of each magnetic core 2.

[0056] Each leg 7 forms the end face 4 of the magnetic core 2. When in the assembled state (see...) Figure 1b and Figure 8 The end faces 4 of the two magnetic cores 2 are separated from each other to form a gap 3.

[0057] Typically, the current in the winding 5 generates a magnetic field in the core 2. This magnetic field passes through the gap 3. However, this gap 3 typically generates gap edge fields formed at its periphery. These edge fields do not typically pass directly through the gap 3 along a straight line between the two opposing end faces 4 of the legs 7 of the core 2, but rather extend outward from the gap. To mitigate or shield these edge fields, the magnetic component 1 also includes shielding devices 10 for shielding the edge fields of the gap 3 respectively. In other words, since the magnetic component 1 of this embodiment includes two gaps 3, the magnetic component 1 also includes two shielding devices 10.

[0058] Figure 7c The structure of the shielding device 10 of the magnetic component 1 in this embodiment is shown in more detail.

[0059] from Figure 7c It can be seen that the shielding device 10 includes a holding unit 11 and three shielding components 12.

[0060] In this embodiment, the retaining unit 11 is rectangular-cubic in shape. Here, the retaining unit 11 includes three side surfaces 13, each configured to retain a shielding member 12. Figure 1a and Figure 1b As can be seen, in this embodiment, the shielding device 10 of the magnetic component is attached and clamped between the two end faces 4 of the two legs 7 of the magnetic core 2. For this purpose, the retaining unit 11 includes two receiving portions 14 between the side surfaces 13, wherein each receiving portion 14 receives one end face 4 of the magnetic core 2.

[0061] The retaining unit 11 also includes a spacer portion 15 protruding from the side surface 13 into the gap 3. The spacer portion 15 separates the opposing end faces 4 of the magnetic core 2. Thus, the spacer portion 15 provides the gap 3 between the end faces 4 of the legs 7 of the magnetic core 2. Furthermore, especially from... Figure 7c As can be seen, the spacer portion 15 is frame-shaped. That is, the spacer portion 15 is generally rectangular in shape with an opening 16. In this embodiment, the spacer portion 15 also includes an L-shaped slot 18 at each corner. The opening 16 and slot 18 of the spacer portion define an air gap in the gap 3 between the end faces 4 of the magnetic core 2.

[0062] As described above, the shielding device 10 includes three shielding members 12. These shielding members 12 are formed of ferrite material. Therefore, the shielding members 12 can be magnetized but are non-conductive, i.e., electrically insulating. Here, the shielding members 12 may include hard ferrite material and / or soft ferrite material, or may be composed entirely of hard ferrite material and / or soft ferrite material. In particular, the shielding members 12 are ferrite plates, i.e., formed of ferrite material and plate-shaped.

[0063] Thus, the shielding member 12 attached to the holding unit 11 can shield the magnetic edge field generated in the gap 3, especially the magnetic edge field passing through the air gap formed by the opening 16 of the spacer portion 15 of the holding unit 11, which is attached to and sandwiched between the end faces 4 of the legs 7 of the magnetic core 2.

[0064] Furthermore, the retaining unit 11 includes two shielding member spacers 17, each spacer protruding vertically from a corresponding side surface 13 of the retaining unit 11. These spacers 17 provide a gap between the shielding members 12. The thickness of the spacers 17 in a direction parallel to the extending direction of the corresponding surface 13, as well as their material composition, can be used to adjust the magnetism of the shielding device 10.

[0065] As will refer to Figure 8 In more detail, the thickness of the side surface 13 and other dimensions of the retaining unit 11, such as height, width, and depth, are adjusted to provide excellent edge field shielding through the shielding member 12, while also preventing magnetic short circuits through the shielding member 12.

[0066] Figure 2a and Figure 2b A schematic diagram is shown of the magnetic component 1 in a pre-assembled state and an assembled state according to a second embodiment of the present invention. Specifically, Figure 2a The magnetic component 1 is shown in a pre-assembled state, while Figure 2b The magnetic component 1 is shown in its assembled state.

[0067] from Figure 2aAs can be seen, the magnetic component 1 of this embodiment includes two magnetic cores 2, each of which is E-shaped, commonly referred to as an "EE configuration". In other words, each magnetic core 2 of the magnetic component 1 of this embodiment includes three legs 7, whose opposing end faces 4 form a total of three gaps 3. In this embodiment, the magnetic component 1 includes two shielding devices 10 as described with respect to the first embodiment.

[0068] In addition, the magnetic component 1 of this embodiment includes two additional shielding devices 10, which will now be referred to... Figure 7a Explain it.

[0069] from Figure 7a It can be seen that the additional shielding device 10 includes a U-shaped retaining unit 11 and a shielding member 12. In this case, the retaining unit 11 includes three side surfaces 13, of which two side surfaces 13 ( Figure 7a The left and right side surfaces 13 are substantially larger than the other side surface 13. Figure 7a The top side surface 13) is short.

[0070] Using this structure, such as Figure 2a As shown, the retaining unit 11 and thus the entire additional shielding device 10 can be attached to the outer surface 6 of the magnetic core 2, wherein the outer surface 6 does not include the end face 4 of the magnetic core 2.

[0071] Therefore, from Figure 2b It can be seen that the aforementioned additional shielding device 10 can also be attached to the outer surface 6 of the middle leg 7 of the magnetic core 2. Thus, the shielding device 10 can shield the gap edge field generated in the gap 3 between the middle legs 7 of the two E-shaped magnetic cores 2. Furthermore, the magnetic component 1 of this embodiment includes a second additional shielding device 10, which is disposed on the outer surface 6 of the bottom side of the two magnetic cores 2.

[0072] In this embodiment, the additional shielding device 10 can also be attached to the outer surface 6 of the other legs 7 (left leg and right leg 7). Furthermore, the shielding device 10 can also be attached to the electrical winding 5, particularly to its outer side.

[0073] In this embodiment, the retaining unit 10 is configured to engage with the outer surfaces 6 of the two magnetic cores 2 and / or with the electrical winding 5.

[0074] Furthermore, in this embodiment Figure 7a The aforementioned shielding device 10 shown may further include a spacer portion 15 (not shown). In this case, the spacer portion 15 extends from... Figure 7a The top side surface 13 protrudes into the gap 3. In other words, when the retaining unit 11 is engaged with or otherwise attached to, for example, the outer surface 6 of the middle leg 7, its spacer portion 15 can be inserted into the gap 3 between the middle legs 7.

[0075] Figure 3a and Figure 3b A schematic diagram is shown of the magnetic component 1 in a pre-assembled state and a post-assembled state according to a third embodiment of the present invention. Specifically, Figure 3a The magnetic component 1 is shown in a pre-assembled state, while Figure 3b The magnetic component 1 is shown in its assembled state.

[0076] In this embodiment, the magnetic component 1 also includes two E-shaped magnetic cores 2 and four electrical windings 5 ​​respectively disposed between the three legs 7 of each magnetic core 2.

[0077] In this embodiment, in addition to the two shielding devices 10 described with respect to the first embodiment, the magnetic component 1 also includes another shielding device 10; as from Figure 7b As can be seen in more detail, the retaining unit 11 of the additional shielding device 10 is also U-shaped. Among them, the two side surfaces 13 ( Figure 7b The left and right side surfaces 13 are at least as long as or longer than the top side surface 13 of the retaining unit 11. In addition, the additional shielding device 10 here includes two shielding members 12, each shielding member 12 being disposed on one of the left and right side surfaces 13.

[0078] like Figure 3a and Figure 3b As shown in the comparison, the additional shielding device 10 in this embodiment is configured to slide onto the outer surfaces 6 of the two magnetic cores 2. Here, the additional shielding device 10 is attached to the outer surface 6 of the intermediate leg 7.

[0079] Using this construction, only one additional shielding device 10 is used to cover the intermediate gap 3 between the intermediate legs 7.

[0080] Figure 4a and Figure 4b A schematic diagram is shown of the magnetic component 1 in a pre-assembled state and a post-assembled state according to a fourth embodiment of the present invention. Specifically, Figure 4a The magnetic component 1 is shown in a pre-assembled state, while Figure 4b The magnetic component 1 is shown in its assembled state.

[0081] In this embodiment, the magnetic component 1 includes two magnetic cores 2 of different shapes. In particular, the magnetic component 1 includes a first magnetic core 2 in the shape of a U and another magnetic core 2 having a substantially elongated rectangular shape (I-shape). This configuration is often referred to as a "UI configuration".

[0082] In this embodiment, the magnetic component 1 includes two shielding devices 10, which have the characteristics described above in the first embodiment and Figure 7c The structure of the shielding device 10 is described. Furthermore, the magnetic component 1 includes two electrical windings 5, each configured to surround a leg 7 of the U-shaped magnetic core 2.

[0083] In this embodiment, the shielding device 10 is sandwiched between the U-shaped magnetic core 2 and the I-shaped magnetic core 2, as well as... Figure 4b As shown.

[0084] Figure 5a and Figure 5b A schematic diagram is shown of the magnetic component 1 in a pre-assembled state and a post-assembled state according to a fifth embodiment of the present invention. Specifically, Figure 5a The magnetic component 1 is shown in a pre-assembled state, while Figure 5b The magnetic component 1 is shown in its assembled state.

[0085] In this embodiment, the magnetic component 1 also includes the UI structure of the magnetic core 2 described above. In this embodiment, the magnetic component 1 includes a shielding device 10, which will now be referred to... Figure 7d Explain it.

[0086] from Figure 7d As can be seen, the holding unit 11 of the shielding device 10 in this embodiment has a rectangular shape and includes two spacer portions 15, each spacer portion having an opening 16. Here, a receiving portion 14 (e.g., Figure 7d The top side of the receiving portion 14 is configured to receive the entire I-shaped magnetic core 2. In other words, the magnetic core 2 can be completely inserted into the receiving portion 14. Furthermore, the second receiving portion 14 ( Figure 7d The bottom side of the U-shaped magnetic core 2 is configured to receive two legs 7. Each leg 7 abuts against a spacer portion 15 of the holding unit 11.

[0087] Furthermore, the holding unit 11 of the shielding device 10 in this embodiment includes four side surfaces 13, each side surface holding a shielding member 12. Two of the side surfaces 13 ( Figure 7d The top and bottom surfaces are constructed to be larger than the other two side surfaces 13. Figure 7d (Left and right sides) length. However, the retaining unit 11 can also be generally formed as a square, which is related to the fact that the (I-shaped) magnetic core 2 may be square.

[0088] Therefore, from Figure 5b As can be seen, the magnetic component 1 in this embodiment includes a single shielding device 10, which completely surrounds the two gaps 3 between the two legs 7 of the U-shaped magnetic core 2 and the opposite end face 4 of the I-shaped magnetic core 2.

[0089] Figure 6a and Figure 6bA schematic diagram is shown of the magnetic component 1 in a pre-assembled state and a post-assembled state according to a sixth embodiment of the present invention. Specifically, Figure 6a The magnetic component 1 is shown in a pre-assembled state, while Figure 6b The magnetic component 1 is shown in its assembled state.

[0090] In this embodiment, the magnetic component 1 includes four magnetic cores 2, all of which are I-shaped. Here, the magnetic component 1 includes two shielding devices 10 according to the foregoing description of the fifth embodiment of the present invention, namely… Figure 7d The shielding device 10 shown.

[0091] Here, each shielding device 10 is attached to and sandwiched between three magnetic cores 2. Specifically, two intermediate magnetic cores 2, including the electrical winding 5, are inserted into the receiving section 14. Figure 6a and Figure 6b The left receiving portion 14 of the right shielding device 10 and the right receiving portion 14 of the left shielding device 10. In addition, other I-shaped magnetic cores 2 are each inserted into other receiving portions 14 of each shielding device 10.

[0092] Therefore, from Figure 6b It can be seen that the two shielding devices 10 cover and shield the four gaps 3.

[0093] Figure 8 This is a schematic cross-sectional view of the magnetic component 1 according to the foregoing embodiment of the present invention. Specifically, Figure 8 A cross-sectional view along line AA of the magnetic component 1 of the first embodiment is shown. However, regarding... Figure 8 The following description can also be applied to embodiments 2 to 6 of the present invention.

[0094] For the sake of simplicity, the holding unit 11 of the shielding device 10 is omitted, and only one shielding member 12 is shown.

[0095] Here, the width of gap 3 is defined as “D”. In addition, the shortest distance between the shielding member 12 and the nearest edge 19 of the corresponding gap 3 is defined as “L”.

[0096] Typically, the retaining unit 11 retains the corresponding shielding member 12 such that L > D. For example, in the first embodiment of the invention, L equals 1.5 × D. In other words, the quotient of L / D is equal to 1.5.

[0097] Thus, the shielding member 12 can optimally shield the gap edge field around the gap 3 without causing a magnetic short circuit.

[0098] In addition, from Figure 8 It can be seen that the shielding component 12 overlaps with the two end faces 4 of the corresponding magnetic core 2.

[0099] In all the foregoing embodiments, the retaining unit 11 is an electrical insulator formed of, for example, plastic.

[0100] Furthermore, in all the foregoing embodiments, the electrical winding 5 is shown preferably configured not to surround the gap 3. This has the advantage of reducing AC losses in the magnetic component 1, while the shielding device 10 provides eddy field shielding.

[0101] Furthermore, in one or all of the foregoing embodiments, the magnetic component 1 preferably does not include a spool. Instead, the electrical winding 5 is wound directly around the magnetic core 2.

[0102] In all the foregoing embodiments, the retaining unit 11 is used to fix the shielding member 12 and set the distance between the shielding member 12 and the magnetic core 2, in particular the distance L, so as to avoid and prevent magnetic short circuits.

[0103] Furthermore, the retaining unit 11 serves as an air gap spacer between the opposing end faces 4, and thus sets the inductance of the magnetic component 1 and increases the saturation current of the magnetic component 1.

[0104] Furthermore, the advantage of retaining unit 11 is that it helps guide the magnetic core during the assembly process for better alignment.

[0105] The retaining unit 11 can also be used as a spacer to separate the electric winding 5 from the gap 3, which reduces the AC resistance of the electric winding 5.

[0106] In addition, the retaining unit 11 can also be used as a spacer to separate the electric winding 5 from the magnetic core 2, so as to increase the creepage distance and gap distance, and provide better insulation.

[0107] The magnetic component 1 described above can be used, for example, in power converters, particularly in switch-mode power converters.

[0108] The magnetic component 1 may generally include one or more shielding devices 10.

[0109] Figure 9 and Figure 10 This illustrates how, for all the above embodiments, the core plate 20 can be attached to the retaining unit 11 for air gap distribution. The retaining unit 11 positions the core plate 20 within the gap 3 for air gap distribution.

[0110] The core plate 20 is perpendicular to the shielding member 12. A retaining unit 11 separates the core plate 20 from the two opposing end faces 4 of the magnetic core 2. Furthermore, the retaining unit 11 separates the core plates 20 from each other via a partition wall 22. An insertion portion 21 for each core plate 20 is formed in the retaining unit 11. The insertion portion 21 is a sliding groove for sliding the core plate 20. Moreover, the retaining unit 11 is a single component that retains the shielding member 12 and the core plate 20.

[0111] In summary, the magnetic component 1 of the foregoing embodiments provides lower AC loss and higher power efficiency, better EMI behavior, reduced overall size of the magnetic component 1 and thus higher device power density, simplified manufacturing process via the multifunctional holding unit 11, and lower material and labor costs for the entire device including the magnetic component 1.

Claims

1. A magnetic component, comprising: At least two magnetic cores, wherein at least one gap is formed between two opposing end faces of the at least two magnetic cores; At least one electrical winding that surrounds at least one or at least a portion of one or both of the at least two magnetic cores, and not around the at least one gap; and A shielding device for shielding the edge field of the at least one gap along at least a portion of its periphery, the shielding device comprising: A retaining unit, attached between the two opposing end faces of the at least two magnetic cores, at the periphery of the at least one gap; and At least one shielding member is attached to the retaining unit; The retaining unit has at least one side surface extending beyond the at least one gap and the two opposing end faces, and the at least one shielding member is configured to be disposed outside the retaining unit to shield the gap edge field around the at least one gap.

2. The magnetic component according to claim 1, wherein, The at least one side surface is configured to at least partially surround the at least one gap and retain the at least one shielding member.

3. The magnetic component according to claim 2, wherein, The holding unit includes a receiving portion located between a plurality of side surfaces and configured to receive one of the two opposing end faces, and the holding unit includes a further receiving portion located between the plurality of side surfaces and configured to receive the other of the two opposing end faces.

4. The magnetic component according to claim 1, wherein, The retaining unit is attached only to the outer surface of the at least two magnetic cores, excluding the end face.

5. The magnetic component according to claim 4, wherein, The retaining unit engages with the outer surface of at least one magnetic core.

6. The magnetic component according to claim 1, wherein, The retaining unit includes at least one spacer portion that protrudes from the at least one side surface into the at least one gap, and separates at least two opposing end faces with respect to the spacer portion.

7. The magnetic component according to claim 6, wherein, The spacer portion is frame-shaped, and an air gap is defined in the gap between the end faces through the opening of the frame-shaped spacer portion.

8. The magnetic component according to claim 6, wherein, The spacer portion fills the gap between the end faces.

9. The magnetic component according to any one of claims 1-8, wherein, The retaining unit includes at least one shielding member spacer that protrudes from the side surface of the retaining unit to separate the two shielding members respectively.

10. The magnetic component according to any one of claims 1-8, in, The shortest distance between the shielding member and the nearest edge of the corresponding gap is defined as L, and the width of the corresponding gap is defined as D, where L>D.

11. The magnetic component according to claim 10, wherein, The quotient of L / D is between a maximum value and a minimum value, including the maximum value and the minimum value, wherein the maximum value is any one of 5, 3, 2, and / or the minimum value is any one of 1.1, 1.2, 1.3, 1.4, 1.5, and / or the quotient of L / D is one of the above values.

12. The magnetic component according to any one of claims 1-8, wherein, The shielding member overlaps with at least one of the end faces.

13. The magnetic component according to any one of claims 1-8, wherein, The at least one shielding component is a ferrite plate.

14. The magnetic component according to any one of claims 1-8, wherein, The retaining unit is an electrical insulator and comprises or is composed of plastic or ceramic materials.

15. The magnetic component according to any one of claims 1-8, wherein, At least one core plate is attached to the retaining unit and positioned by the retaining unit within the gap.

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