Magnetic assembly

Abstract

The invention provides a magnetic assembly. The magnetic assembly comprises a first magnetic core, a second magnetic core and a coil, the first magnetic core includes a first magnetic cover and a first guide portion. The second magnetic core includes a second magnetic cover and a second guide portion. The first magnetic core and the second magnetic core are in butt joint in the axial direction to form a wrapping post. The wrapping post is provided with a first end and a second end which are oppositely arranged in the axial direction, the first magnetic cover is located at the first end, the second magnetic cover is located at the second end, the first guide part is adjacent to the first end and located on the first magnetic cover, and the depth of the second magnetic cover embedded in the first magnetic cover is increased in the direction from the second magnetic cover to the first magnetic cover. The second guide part is adjacent to the second end and is located on the second magnetic cover, and the depth of the second guide part embedded in the second magnetic cover is increased from the first magnetic cover to the second magnetic cover. The coil is wound on the wrapping post at a spiral angle relative to the wrapping post and comprises a first wire outlet end and a second wire outlet end. The first wire outlet end is led out along the first guide part, and the second wire outlet end is led out along the second guide part.

Description

Technical Field

[0001] The invention relates to an assembly structure of an electronic component, in particular to a magnetic component with an improved structure. Background Art

[0002] As the functions of electrical equipment increase and their performance improves, the power handled by the components inside the power supply is getting larger and larger. In particular, high power density occasions require the size of magnetic components to be as small as possible and require the magnetic components to have a certain overload capacity, which puts higher demands on the heat dissipation and anti-saturation of magnetic components. At the same time, in order to meet the opportunities and challenges of Industry 4.0 and Smart Manufacturing 2035, digitalization and automation will be further integrated, that is, with the investment of industrial robots and automation equipment, magnetic components need to be automated, which also puts higher requirements on the assembly of magnetic components.

[0003] For magnetic components, when the cross-sectional area of ​​the core is constant, under the same inductance and working conditions, the more turns the coil has, the greater its anti-saturation ability, the greater the coil loss, and the more difficult it is to dissipate heat. Especially in low-voltage and high-current working conditions, in order to withstand high currents, large-diameter wires are required. The wires need to be wound along the axial direction of the core column in a spiral ascending structure, resulting in different heights of the coils. When equipping the core, the core window height needs to be configured based on the maximum height of the coil and a certain margin (such as 0.2mm), resulting in some waste of space.

[0004] For the coil, the larger the wire size along the axial winding direction, the greater the height difference produced after each spiral rise. After the coil and the magnetic core are assembled, more space is wasted and the degree of skewness is more serious, making it more difficult to achieve automated assembly with the magnetic core.

[0005] On the other hand, for the core structure of low-voltage and high-current magnetic components, the core window is usually made of the same height at all places. The coil is made of tinned copper sheet or enameled copper (round or flat) wire. If tinned copper sheet is used, the coil is relatively simple to form, but it uses a stamping process (later tinning), which consumes more materials, and the coil turns need air distance or physical isolation such as tape for insulation, which increases the coil height and causes a larger inductance size; if enameled copper (round or flat) wire is used, there is a lacquer layer between the coil turns and between the coil and the core for insulation, but because the wire is wound along the axial direction of the core winding column in a spiral ascending structure, the height of the coil at both ends is different, and the window height of the core will be higher than the maximum height of the coil, resulting in a larger core size and difficulty in improving the power density. When the number of turns (>=2) is less, the line width accounts for a larger proportion of the total coil height, and this problem will become more serious.

[0006] In view of this, it is necessary to provide a magnetic component with an improved structure to reduce the waste of coil space, improve power density, and solve the defects of the prior art. Summary of the invention

[0007] The purpose of the present invention is to provide a magnetic component with an improved structure. The magnetic core is improved in structure (for example, a spiral, sloped or stepped groove) at the outlet position of the coil to ensure that the outlet position does not affect the assembly of the magnetic core, thereby achieving that the height of the magnetic core does not need to be designed according to the maximum coil size, and the number of coil turns can be appropriately increased in situations where there is an overload demand, thereby enhancing the anti-saturation ability of the magnetic component and improving the power density of the magnetic component, wherein the groove structure and the coil shape are basically matched, and the coil is not easy to be skewed during assembly, meeting the requirements of automated production, improving quality and reducing costs.

[0008] Another object of the present invention is to provide a magnetic component with an improved structure. The inner wall of the magnetic core is processed into a spiral, sloped or stepped groove structure, the height dimension of the magnetic core window occupied by the coil outlet is reduced, the utilization rate of the magnetic core window is improved, and the purpose of increasing the number of coil turns, increasing the cross-sectional area of ​​the wire or reducing the height dimension of the magnetic core winding column is achieved. In addition, the matching degree between the magnetic core and the coil is improved, which helps to realize the efficient automatic assembly of the coil and the magnetic core.

[0009] To achieve the above-mentioned purpose, one aspect of the present invention provides a magnetic component, including a first magnetic core, a second magnetic core and a coil. The first magnetic core includes a first magnetic cover and a first guide portion. The second magnetic core includes a second magnetic cover and a second guide portion, wherein the first magnetic core and the second magnetic core are butted together along an axial direction to form a winding column, wherein the winding column has a first end and a second end arranged opposite to each other along the axial direction, the first magnetic cover is located at the first end, the second magnetic cover is located at the second end, the first guide portion is adjacent to the first end and is located on the first magnetic cover, and the depth of the first magnetic cover embedded in the first magnetic cover is increased from the second magnetic cover toward the first magnetic cover, the second guide portion is adjacent to the second end and is located on the second magnetic cover, and the depth of the second magnetic cover embedded in the second magnetic cover is increased from the first magnetic cover toward the second magnetic cover. The coil is wound on the winding column at a spiral angle α relative to the winding column, and includes a first outlet end and a second outlet end, wherein the first outlet end is led out along the first guide portion, and the second outlet end is led out along the second guide portion.

[0010] In one embodiment, the coil is wound around a winding post M times, where M is an integer greater than or equal to 2, and the circumference C of the inner diameter of the coil in each turn of the coil is greater than or equal to the circumference C′ of the winding post, and the coil width W increases axially with each turn of the coil, wherein the coil has a line width W′ and is wound around the winding post according to a winding coefficient A, and the coil width W satisfies: W=W′·A.

[0011] In one embodiment, the inner diameter length of the coil disposed in the first guide portion is S1, and the inner diameter length of the coil disposed in the second guide portion is S2.

[0012] In one embodiment, the inner diameter lengths S1 and S2 of the coil are equal.

[0013] In one embodiment, the first guide portion and the second guide portion are spiral grooves, and the shapes of the first guide portion and the second guide portion match the shapes of the first outlet terminal and the second outlet terminal.

[0014] In one embodiment, the first guide portion forms a first sloped groove along the first wire end toward a side away from the first wire end, and the second guide portion forms a second sloped groove along the second wire end toward a side away from the second wire end, the inclination angle β of the first guide portion and the second guide portion is greater than the spiral angle α of the first wire end and the second wire end, and along the axial direction, the depth D1 of the first sloped groove is greater than the extended width H1 of the first wire end, and the depth D2 of the second sloped groove is greater than the extended width H2 of the second wire end.

[0015] In one embodiment, the first guide portion forms a first stepped groove along the first outlet end toward a side away from the first outlet end, and the second guide portion forms a second stepped groove along the second outlet end toward a side away from the second outlet end, and along the axial direction, a depth D1 of the first stepped groove is greater than an extended width H1 of the first outlet end, and a depth D2 of the second stepped groove is greater than an extended width H2 of the second outlet end.

[0016] In one embodiment, the extension width H1 of the first outlet terminal satisfies: The extension width H2 of the second outlet terminal satisfies:

[0017] In one embodiment, the winding coefficient A ranges from 1 to 1.5.

[0018] In one embodiment, the winding coefficient A ranges from 1.05 to 1.15.

[0019] In one embodiment, the helix angle α satisfies:

[0020] In one embodiment, the coil and the winding post have a matching gap X.

[0021] In one embodiment, along a direction parallel to the side edges of the first magnetic cover and the second magnetic cover, the first outlet terminal and the second outlet terminal are respectively led out from the first guiding portion and the second guiding portion.

[0022] In one embodiment, the first magnetic core is an I-shaped magnetic core, and the winding post is disposed on a side of the second magnetic cover close to the first magnetic cover.

[0023] In one embodiment, the second magnetic core further includes a third guide portion, which is disposed on a side of the second magnetic cover away from the first magnetic cover and spatially corresponding to the first guide portion along the axial direction, wherein the third guide portion and the first guide portion have the same structure.

[0024] In one embodiment, the magnetic component includes a first magnetic core, N second magnetic cores, N second guide portions, N third guide portions, N winding poles and N coils, where N is an integer and is greater than or equal to 2, the N second magnetic cores are connected in series along the axial direction, the N winding poles are arranged in parallel along the axial direction, and the N coils are respectively wound on the N winding poles.

[0025] In one embodiment, the magnetic component includes N first guide portions, N second guide portions, N winding poles and N coils, where N is an integer greater than or equal to 2, the N winding poles are arranged in parallel or in an array along a direction perpendicular to the axis, and the N coils are respectively wound on the N winding poles.

[0026] In one embodiment, the first magnetic core also includes a first boss, which is adjacent to the first end and located on the first magnetic cover, and protrudes from the first magnetic cover toward the second magnetic cover, and along the axial direction, the first boss is arranged at least relative to a portion of the second guide portion; the second magnetic core also includes a second boss, which is adjacent to the second end and located on the second magnetic cover, and protrudes from the second magnetic cover toward the first magnetic cover, and along the axial direction, the second boss is arranged at least relative to a portion of the first guide portion.

[0027] In one embodiment, the first guide portion increases a first depth D1 from the second magnetic cover toward the first magnetic cover, and the second guide portion increases a second depth D2 from the first magnetic cover toward the second magnetic cover, wherein the first depth D1 and the second depth D2 are equal.

[0028] In one embodiment, the cross section of the winding rod perpendicular to the axial direction is circular, racetrack-shaped or rounded rectangular.

[0029] In one embodiment, the magnetic component is suitable for a conventional inductor, an array inductor, a coupled inductor, a conventional transformer or an array transformer with low voltage and high current.

[0030] In one embodiment, the coil is a round wire or a flat wire.

[0031] The beneficial effect of the present invention is that an embodiment of the present invention provides a magnetic component with an improved structure. The magnetic core reduces the size of the magnetic core window occupied by the coil outlet by improving the structure (for example, a spiral, sloped or stepped groove) at the coil outlet position, improves the utilization rate of the magnetic core window, and increases the number of coil turns or increases the cross-sectional area of ​​the coil or reduces the height of the magnetic core winding column. At the same time, it is ensured that the outlet position does not affect the magnetic core assembly, thereby achieving that the height of the magnetic core does not need to be designed according to the maximum coil size. In situations where there is an overload demand, the number of coil turns can be appropriately increased to enhance the anti-saturation ability of the magnetic component and improve the power density of the magnetic component. The shape of the coil can better match the groove structure of the magnetic core, so that the coil is not easily skewed when assembled on the magnetic core, meeting the requirements of automated production, improving quality and reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The following detailed description of the present invention and the schematic diagrams of the embodiments are intended to enable those skilled in the art to more fully understand the above contents, and are not intended to limit the present invention.

[0033] Figure 1 A structural stereogram of a magnetic assembly according to a first embodiment of the present invention is disclosed;

[0034] Figure 2 A top view of a magnetic assembly according to a first embodiment of the present invention is disclosed;

[0035] Figure 3 Disclosed is a structural exploded view of a magnetic assembly according to a first embodiment of the present invention from a top view;

[0036] Figure 4 A structural exploded view of a magnetic assembly according to a second embodiment of the present invention is disclosed in a top view;

[0037] Figure 5 Disclosed is a structural exploded view of a magnetic assembly according to a second embodiment of the present invention from a side perspective;

[0038] Figure 6 A structural exploded view of a magnetic assembly according to a third embodiment of the present invention is disclosed in a top view;

[0039] Figure 7 A structural exploded view of a magnetic assembly according to a third embodiment of the present invention is disclosed from a side perspective;

[0040] Figure 8 A structural stereogram of a magnetic assembly according to a fourth embodiment of the present invention is disclosed;

[0041] Fig. 9 Discloses a structural exploded view of a magnetic assembly according to a fourth embodiment of the present invention;

[0042] Fig.10 A structural stereogram of a magnetic assembly according to a fifth embodiment of the present invention is disclosed;

[0043] Fig.11 Discloses a structural exploded view of a magnetic assembly according to a fifth embodiment of the present invention;

[0044] Fig.12 A schematic diagram of a flat wire coil flatly wound on a rounded rectangular winding post from a top view is disclosed;

[0045] Fig.13A and Fig. 13B A schematic diagram of a flat wire coil flatly wound on a rounded rectangular winding post in an axial direction is disclosed;

[0046] Fig.14 A structural stereogram of a magnetic assembly according to a sixth embodiment of the present invention is disclosed;

[0047] Fig.15 Discloses a structural exploded view of a magnetic assembly according to a sixth embodiment of the present invention;

[0048] Fig.16 A structural stereogram of a magnetic assembly according to a seventh embodiment of the present invention is disclosed;

[0049] Fig.17 Discloses a structural exploded view of a magnetic assembly according to a seventh embodiment of the present invention;

[0050] Fig.18 A structural stereogram of a magnetic assembly according to an eighth embodiment of the present invention is disclosed;

[0051] Fig.19 An exploded view of a magnetic assembly according to an eighth embodiment of the present invention is disclosed;

[0052] Fig. 20 A schematic diagram of the first magnetic core structure of a magnetic assembly according to an eighth embodiment of the present invention is disclosed;

[0053] Fig.21 A schematic diagram of a coil wound on a magnetic core in an eighth embodiment of a magnetic assembly according to the present invention in an axial direction is disclosed;

[0054] Fig. 22 A schematic diagram of a coil wound on a magnetic core in a magnetic assembly according to an eighth embodiment of the present invention is disclosed from a top view;

[0055] Fig.23 A structural stereogram of a magnetic assembly according to a ninth embodiment of the present invention is disclosed;

[0056] Fig.24 A schematic diagram of a coil wound on a magnetic core in a magnetic assembly according to a ninth embodiment of the present invention is disclosed from a top view;

[0057] Fig.25 Disclose a structural side view of a first magnetic core and a second magnetic core of a magnetic assembly according to a ninth embodiment of the present invention; and

[0058] Fig.26A and Fig.26B A schematic diagram of a coil in a magnetic assembly according to a ninth embodiment of the present invention viewed in an axial direction is disclosed. DETAILED DESCRIPTION

[0059] Some typical embodiments that embody the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can have various changes in different ways, all of which do not depart from the scope of the present invention, and the description and drawings therein are essentially used for illustrative purposes rather than for limiting the present invention. For example, if the following content of the present disclosure describes that a first feature is set on or above a second feature, it means that it includes an embodiment in which the first feature set is in direct contact with the second feature, and also includes an embodiment in which the additional feature can be set between the first feature and the second feature, so that the first feature and the second feature may not be in direct contact. In addition, different embodiments of the present disclosure may use repeated reference symbols and / or marks. These repetitions are for the purpose of simplification and clarity, and are not used to limit the relationship between the various embodiments and / or the appearance structure. Furthermore, in order to facilitate the description of the relationship between a component or feature component and another (plural) component or (plural) feature component in the figure, spatially related terms such as "upper", "lower", "top", "bottom" and similar terms may be used. In addition to the orientation shown in the figure, spatially related terms are used to cover different orientations of the device in use or operation. The device may also be positioned in another way (e.g., rotated 90 degrees or located in other orientations), and the description of the spatially related terms used is interpreted accordingly. In addition, when a component is referred to as "connected to" or "coupled to" another component, it may be directly connected to or coupled to another component, or there may be an intervening component. Although the numerical range and parameters of the broad scope of the present disclosure are approximate values, the numerical values ​​are stated in the specific examples as accurately as possible. In addition, it is understood that although the words "first", "second", "third" and the like may be used in the claims to describe different components, these components should not be limited by these terms, and the components described accordingly in the embodiments are represented by different component symbols. These terms are for different components respectively. For example: the first component may be referred to as the second component, and similarly, the second component may also be referred to as the first component without departing from the scope of the embodiment. The term "and / or" used in this way includes any or all combinations of one or more related listed items.

[0060] Figure 1 A structural stereogram of a magnetic assembly according to a first embodiment of the present invention is disclosed. Figure 2 A top view of a magnetic assembly according to a first embodiment of the present invention is disclosed. Figure 3The structure decomposition diagram of the magnetic component of the first embodiment of the present invention in a top view is disclosed. In this embodiment, the present invention provides a magnetic component 1 suitable for conventional inductors, array inductors, coupled inductors, conventional transformers or array transformers with low voltage and high current. The magnetic component 1 includes a first magnetic core 10, a second magnetic core 20 and a coil 40. The first magnetic core 10 includes a first magnetic cover 11 and a first guide portion 12. The second magnetic core 20 includes a second magnetic cover 21 and a second guide portion 22. The first magnetic core 10 and the second magnetic core 20 are butt-jointed along an axial direction J to form a winding column 30. In this embodiment, the winding column 30 has a first end 31 and a second end 32 arranged opposite to each other along the axial direction J. The first magnetic cover 11 is located at the first end 31, and the second magnetic cover 21 is located at the second end 32. The first guide portion 12 is adjacent to the first end 31 and is located on the first magnetic cover 11, and the depth of the first magnetic cover 11 is increased from the second magnetic cover 21 toward the first magnetic cover 11. In addition, the second guide portion 22 is disposed adjacent to the second end 32 and is located on the second magnetic cover 21, and the depth of the second magnetic cover 21 increases from the first magnetic cover 11 toward the second magnetic cover 21. The coil 40 is wound on the winding post 30 at a spiral angle α relative to the winding post 30, and includes a first outlet terminal 41 and a second outlet terminal 42. The first outlet terminal 41 is led out along the first guide portion 12, and the second outlet terminal 42 is led out along the second guide portion 22.

[0061] In this embodiment, the cross section of the winding post 30 perpendicular to the axial direction J is a racetrack shape. In other embodiments, the cross section of the winding post 30 perpendicular to the axial direction J may also be a circular or rounded rectangular shape. In this embodiment, the coil 40 is a flat wire. In other embodiments, the coil 40 may also be a round wire. In this embodiment, the first guide portion 12 and the second guide portion 22 are spiral grooves. That is, the shapes of the first guide portion 12 and the second guide portion 22 match the shapes of the first outlet terminal 41 and the second outlet terminal 42. In this embodiment, the first guide portion 12 increases a first depth D1 from the second magnetic cover 21 toward the first magnetic cover 11 (i.e., the negative direction of the X-axis), and the second guide portion 22 increases a second depth D2 from the first magnetic cover 11 toward the second magnetic cover 21 (i.e., the positive direction of the X-axis), wherein the first depth D1 and the second depth D2 are equal. The extended width H1 of the first outlet terminal 41 is equal to the extended width H2 of the second outlet terminal 42. In some embodiments of the present invention, the first depth D1 of the first guide portion 12 is greater than the extended width H1 of the first outlet terminal 41, and the second depth D2 of the second guide portion 22 is greater than the extended width H2 of the second outlet terminal. It should be noted that the present invention improves the matching degree of the first magnetic core 10, the second magnetic core 20 and the coil 40 by processing the inner walls of the first magnetic core 10 and the second magnetic core 20 into the first guide portion 12 and the second guide portion 22 that are consistent with the spiral trajectory of the first outlet terminal 41 and the second outlet terminal 42 of the coil 40, which helps to achieve efficient and automated assembly of the coil and the magnetic core. Furthermore, the outlet position of the coil 40 in the first magnetic core 10 and the second magnetic core 20 is improved by the first guide portion 12 and the second guide portion 22, which helps to reduce the height size of the magnetic core window occupied by the coil outlet, improve the utilization rate of the magnetic core window, and further achieve an increase in the number of coil turns or an increase in the cross-sectional area of ​​the wire or a reduction in the height size of the magnetic core winding column. At the same time, it also ensures that the outlet position of the coil 40 does not affect the assembly of the first magnetic core 10 and the second magnetic core 20, so that the height of the magnetic core does not need to be designed according to the maximum coil size. In cases where there is an overload requirement, the number of coil turns can be appropriately increased to enhance the anti-saturation ability of the magnetic component and improve the power density of the magnetic component.

[0062] Figure 4 A structural exploded view of a magnetic component in a top view according to a second embodiment of the present invention is disclosed. Figure 5 The second embodiment of the present invention discloses a structural exploded view of a magnetic component from a side view. In this embodiment, the magnetic component 1' and Figures 1 to 3 The magnetic assembly 1 shown in FIG. 1 is similar, and the same component numbers represent the same components, structures and functions, which will not be described in detail. In this embodiment, the first guide portion 12a forms a first slope-shaped groove along the first outlet end 41 toward the side away from the first outlet end 41, and the second guide portion 22a forms a second slope-shaped groove along the second outlet end 42 toward the side away from the second outlet end 42. Specifically, as shown in FIG. Figure 4Taking the second guide portion 22a shown as an example, downward along the axial direction J, the second guide portion 22a gets closer and closer to the edge of the second magnetic cover 21 facing the paper surface, thereby forming a slope shape. The inclination angle β of the first guide portion 12a and the second guide portion 22a is greater than the spiral angle α of the first outlet end 41 and the second outlet end 42. And along the axial direction J, the depth D1 of the first slope-shaped groove of the first guide portion 12a is greater than the extended width H1 of the first outlet end, and the depth D2 of the second slope-shaped groove of the second guide portion 22a is greater than the extended width H2 of the second outlet end. The first guide portion 12a and the second guide portion 22a improve the outlet position of the coil 40 in the first magnetic core 10 and the second magnetic core 20, which helps to reduce the size of the magnetic core window occupied by the coil outlet, improve the utilization rate of the magnetic core window, and further achieve an increase in the number of coil turns or an increase in the cross-sectional area of ​​the wire or a reduction in the height size of the magnetic core winding column.

[0063] Figure 6 A structural exploded view of a magnetic component in a top view according to a third embodiment of the present invention is disclosed. Figure 7 The third embodiment of the present invention discloses a structural exploded view of a magnetic component in a side view. In this embodiment, the magnetic component 1" and Figures 1 to 3 The magnetic assembly 1 shown in the figure is similar, and the same component numbers represent the same components, structures and functions, which will not be repeated here. In this embodiment, the first guide portion 12b forms a first stepped groove along the first outlet end 41 toward the side away from the first outlet end 41, and the second guide portion 22b forms a second stepped groove along the second outlet end 42 toward the side away from the second outlet end 42. Specifically, as Figure 6 Taking the second guide portion 22b shown as an example, there is a height difference between the bottom surface of the second stepped groove and the magnetic cover surface contacting the winding post 30, thereby forming a step. And along the axial direction J, the depth D1 of the first stepped groove of the first guide portion 12b is greater than the extended width H1 of the first outlet end, and the depth D2 of the second stepped groove of the second guide portion 22b is greater than the extended width H2 of the second outlet end. The first guide portion 12b and the second guide portion 22b are used to improve the outlet position of the coil 40 in the first magnetic core 10 and the second magnetic core 20, which helps to reduce the size of the magnetic core window occupied by the coil outlet, improve the utilization rate of the magnetic core window, and further achieve an increase in the number of coil turns or an increase in the cross-sectional area of ​​the wire or a reduction in the height of the magnetic core winding post.

[0064] Figure 8 A structural stereogram of a magnetic assembly according to a fourth embodiment of the present invention is disclosed. Fig. 9 The fourth embodiment of the present invention discloses a structural exploded view of a magnetic component. In this embodiment, the magnetic component 1a and Figures 1 to 3The magnetic component 1 shown is similar, and the same component numbers represent the same components, structures and functions, which will not be repeated here. In this embodiment, the magnetic component 1a includes a first magnetic core 10a, a second magnetic core 20a and two coils 40. The first magnetic core 10a includes a first magnetic cover 11 and two first guide portions 12. The second magnetic core 20a includes a second magnetic cover 21 and two second guide portions 22. The first magnetic core 10a and the second magnetic core 20a are butted along the axial direction J to form two winding posts 30. The two winding posts 30 are arranged in parallel along a direction perpendicular to the axial direction J (for example, the Y-axis direction), and the two coils 40 are respectively wound on the two winding posts 30. As a result, the magnetic component 1a can improve the matching degree between the magnetic core and the coil 40, expand the vertical axial direction J (i.e., the Y-axis direction), and realize efficient and automated assembly of the coil 40 and the magnetic core.

[0065] Fig.10 A structural stereogram of a magnetic assembly according to a fifth embodiment of the present invention is disclosed. Fig.11 The structure of the magnetic component of the fifth embodiment of the present invention is disclosed. In this embodiment, the magnetic component 1b and Figures 1 to 3 The magnetic component 1 shown is similar, and the same component numbers represent the same components, structures and functions, which will not be repeated here. In this embodiment, the magnetic component 1b includes a first magnetic core 10b, a second magnetic core 20b and three coils 40. The first magnetic core 10b includes a first magnetic cover 11 and three first guide portions 12. The second magnetic core 20b includes a second magnetic cover 21 and three second guide portions 22. The first magnetic core 10b and the second magnetic core 20b are connected along the axial direction J to form three winding poles 30. The three winding poles 30 are arranged in parallel along a direction perpendicular to the axial direction J (for example, the Y-axis direction), and the three coils 40 are respectively wound on the three winding poles 30. In one embodiment, the magnetic component 1b may include, for example, N first guide portions 12, N second guide portions 22, N winding posts 30 and N coils 40, where N is an integer greater than or equal to 2, and the N winding posts 30 are arranged in parallel or in an array along a direction perpendicular to the axial direction J, and the N coils 40 are respectively wound on the N winding posts 30. Thus, the magnetic component 1b can improve the matching degree between the magnetic core and the coil 40, expand the vertical axial direction J, and realize efficient and automated assembly of the coil 40 and the magnetic core. Of course, the number and combination of the first guide portion 12, the second guide portion 22, the winding post 30 and the coil 40 can be adjusted according to actual application requirements, and the present invention is not limited thereto.

[0066] In addition, it should be noted that in the aforementioned embodiments, the shapes of the winding post 30 and the coil 40 as well as the number of turns of the coil 40 wound around the winding post 30 can be adjusted according to actual application requirements. Fig.12 A schematic diagram of a flat wire coil wound flat on a rounded rectangular winding post from a top view is disclosed. Fig.13A and Fig. 13BA schematic diagram of a flat wire coil wound flat on a rounded rectangular winding post in the axial direction is disclosed. Figures 1 to 3 , Fig.12 , Fig.13A and Fig. 13B . In one embodiment, the number of turns of the coil 40 wound on the winding post 30 is M turns, where M is an integer greater than or equal to 2. In this embodiment, the number of turns of the coil 40 wound on the winding post 30 is 5 turns. The circumference C of the inner diameter of the coil 40 in each turn is greater than or equal to the circumference C' of the winding post 30, and the coil width W increases along the axial direction J for each turn of the coil 40, wherein the coil 40 has a line width W', and is wound on the winding post 30 according to a winding coefficient A, and the coil width W satisfies: W=W'·A. The range of the winding coefficient A is between 1 and 1.5. In some embodiments of the present invention, the range of the winding coefficient A can also be between 1.05 and 1.15. Then the spiral angle α satisfies:

[0067] In addition, in this embodiment, the first inner diameter length of the coil 40 disposed in the first guide portion 12 is S1, and the second inner diameter length of the coil 40 disposed in the second guide portion 22 is S2. In this embodiment, the first inner diameter length S1 and the second inner diameter length S2 of the coil 40 are equal. Furthermore, in this embodiment, the extended width H1 of the first outlet end 41 of the coil 40 satisfies: The extension width H2 of the second outlet end 42 of the coil 40 satisfies: Thus, the first magnetic core 10 and the second magnetic core 20 can save a dimension H=H1+H2 of the coil 40 in the axial direction J through the structural improvement of the first guide portion 12 and the second guide portion 22. In one embodiment, the extension width H1 of the first outlet end 41 is equal to the extension width H2 of the second outlet end 42. Of course, in other embodiments, the extension width H1 of the first outlet end 41 and the extension width H2 of the second outlet end 42 can be designed with different dimensions, and the present invention is not limited thereto.

[0068] Fig.14 A structural stereogram of a magnetic assembly according to a sixth embodiment of the present invention is disclosed. Fig.15 The sixth embodiment of the present invention discloses a structural exploded view of a magnetic component. In this embodiment, the magnetic component 1c and Figures 1 to 3The power supply device 1 shown is similar, and the same component numbers represent the same components, structures and functions, which will not be repeated here. In this embodiment, the magnetic component 1c includes a first magnetic core 10c, two second magnetic cores 20c and two coils 40. The first magnetic core 10c is an I-shaped magnetic core, and the winding column 30 is arranged on the side of the second magnetic cover 21 close to the first magnetic cover 11. In this embodiment, the second magnetic core 20c also includes a third guide portion 23, which is arranged on the side of the second magnetic cover 21 away from the first magnetic cover 11, and is arranged in space along the axial direction J corresponding to the first guide portion 12, wherein the third guide portion 23 and the first guide portion 12 have the same structure. During assembly, the first magnetic core 10c and the second magnetic core 20c are butt-jointed along the axial direction J to form a winding column 30. The two second magnetic cores 20c are connected in series along the axial direction J. When the coil 40 is wound around the winding post 30 between the first magnetic core 10c and the second magnetic core 20c, the first outlet terminal 41 is led out along the first guide portion 12, and the second outlet terminal 42 is led out along the second guide portion 22. In addition, the two second magnetic cores 20c are connected in series along the axial direction J to form another winding post 30. When the coil 40 is wound around the winding post 30 between the two second magnetic cores 20c, the first outlet terminal 41 is led out along the third guide portion 23, and the second outlet terminal 42 is led out along the second guide portion 22. Thus, the magnetic component 1c can improve the matching degree between the magnetic core and the coil 40, expand the structure along the axial direction J (i.e., the negative direction of the X-axis), and realize efficient and automated assembly of the coil 40 and the magnetic core.

[0069] Fig.16 A structural stereogram of a magnetic assembly according to a seventh embodiment of the present invention is disclosed. Fig.17 The seventh embodiment of the present invention discloses a structural exploded view of the magnetic component. In this embodiment, the magnetic component 1c' and Figure 14 to Figure 15The magnetic component 1c shown is similar, and the same component numbers represent the same components, structures and functions, which will not be repeated here. In this embodiment, the magnetic component 1c' includes a first magnetic core 10c, three second magnetic cores 20c and three coils 40. The first magnetic core 10c is an I-shaped magnetic core, and the winding column 30 is arranged on the side of the second magnetic cover 21 close to the first magnetic cover 11. In this embodiment, the second magnetic core 20c also includes a third guide portion 23, which is arranged on the side of the second magnetic cover 21 away from the first magnetic cover 11, and is arranged spatially along the axial direction J corresponding to the first guide portion 12, wherein the third guide portion 23 and the first guide portion 12 have the same structure. During assembly, the first magnetic core 10c and the second magnetic core 20c are butt-jointed along the axial direction J to form a winding column 30. The three second magnetic cores 20c are connected in series along the axial direction J. When the coil 40 is wound around the winding post 30 between the first magnetic core 10c and the second magnetic core 20c, the first outlet terminal 41 is led out along the first guide portion 12, and the second outlet terminal 42 is led out along the second guide portion 22. In addition, the two second magnetic cores 20c are connected in series along the axial direction J to form another winding post 30. When the coil 40 is wound around the winding post 30 between the two second magnetic cores 20c, the first outlet terminal 41 is led out along the third guide portion 23, and the second outlet terminal 42 is led out along the second guide portion 22. In other embodiments, the magnetic component 1c' includes a first magnetic core 10c, N second magnetic cores 20c, N second guide portions 22, N third guide portions 23, N winding poles 30 and N coils 40, N is an integer and is greater than or equal to 2, the N second magnetic cores 20c are connected in series along the axial direction J, the N winding poles 30 are arranged in parallel along the axial direction J, and the N coils 40 are respectively wound on the N winding poles 30. Thus, the magnetic component 1c' can improve the matching degree between the magnetic core and the coil 40, expand the structure along the axial direction J (i.e., the negative direction of the X-axis), and realize efficient and automated assembly of the coil 40 and the magnetic core. Of course, the present invention is not limited to this. In some embodiments of the present invention, the Nth second magnetic core 20c can also be provided with only a second guide portion 22, without a third guide portion 23. That is, the magnetic component 1c' includes a first magnetic core 10c, N second magnetic cores 20c, N second guide portions 22, N-1 third guide portions 23, N winding poles 30 and N coils 40, N is an integer and is greater than or equal to 2, the N second magnetic cores 20c are connected in series along the axial direction J, the N winding poles 30 are arranged in parallel along the axial direction J, and the N coils 40 are respectively wound on the N winding poles 30.

[0070] Fig.18 A structural stereogram of a magnetic assembly according to an eighth embodiment of the present invention is disclosed. Fig.19 An exploded view of a magnetic assembly according to an eighth embodiment of the present invention is disclosed. Fig. 20 A schematic diagram of the first magnetic core structure of a magnetic component according to an eighth embodiment of the present invention is disclosed. Fig.21A schematic diagram showing an axial view of a coil wound around a magnetic core in a magnetic assembly according to an eighth embodiment of the present invention is disclosed. Fig. 22 The eighth embodiment of the present invention discloses a schematic diagram of a coil wound on a magnetic core in a magnetic component in a top view. In this embodiment, the magnetic component 1d and Figures 1 to 3 The magnetic component 1 shown is similar, and the same component numbers represent the same components, structures and functions, which will not be repeated here. In this embodiment, the magnetic component 1d includes a first magnetic core 10d, a second magnetic core 20d, two coils 40 and a base 50. The first magnetic core 10d includes a first magnetic cover 11 and two first guide portions 12. The second magnetic core 20d includes a second magnetic cover 21 and two second guide portions 22. The first magnetic core 10d and the second magnetic core 20d have the same structure, for example. The first magnetic core 10 and the second magnetic core 20 are butt-jointed along an axial direction J parallel to the X axis to form two circular winding poles 30. In this embodiment, the winding pole 30 has a first end 31 and a second end 32 arranged opposite to each other along the axial direction J. The first magnetic cover 11 is located at the first end 31, and the second magnetic cover 21 is located at the second end 32. The first guide portion 12 is disposed adjacent to the first end 31 and is located on the first magnetic cover 11, and the depth of the first magnetic cover 11 increases from the second magnetic cover 21 toward the first magnetic cover 11 (i.e., the negative direction of the X axis). In addition, the second guide portion 22 is disposed adjacent to the second end 32 and is located on the second magnetic cover 21, and the depth of the second magnetic cover 21 increases from the first magnetic cover 11 toward the second magnetic cover 21 (i.e., the positive direction of the X axis). The coil 40 is wound on the winding post 30 at a spiral angle α relative to the winding post 30, and includes a first outlet terminal 41 and a second outlet terminal 42. The first outlet terminal 41 is led out along the first guide portion 12, and the second outlet terminal 42 is led out along the second guide portion 22.

[0071] In this embodiment, along a direction parallel to the sides of the first magnetic cover 11 and the second magnetic cover 21, i.e., the positive direction of the Z axis, the first outlet terminal 41 and the second outlet terminal 42 are respectively led out from the first guide portion 12 and the second guide portion 22, and connected to the first through hole 51 and the second through hole 52 of the base 50, thereby forming, for example, two inductors.

[0072] In this embodiment, the first magnetic core 10d further includes a first boss 13, which is disposed adjacent to the first end 31 and located on the first magnetic cover 11, and protrudes from the first magnetic cover 11 toward the second magnetic cover 21, and along the axial direction J, the first boss 13 is disposed at least relative to a portion of the second guide portion 22. Similarly, the second magnetic core 20d further includes a second boss 23, which is disposed adjacent to the second end 32 and located on the second magnetic cover 21, and protrudes from the second magnetic cover 21 toward the first magnetic cover 11, and along the axial direction J, the second boss 23 is disposed at least relative to a portion of the first guide portion 12.

[0073] In this embodiment, the coil 40 and the winding post 30 have a matching gap X. The standard line width W′ of the coil 40 is wound on the winding post 30 at a spiral angle α according to the winding coefficient A, forming a coil width W that satisfies: W=W′·A. The winding post 30 has the same radius R. The inner diameter circumference of the coil C=2π(R+X). There is a height h from the center of the winding post 30 to the bottom surface of the magnetic core on the outlet side (i.e., the surface of the base 50). The inner diameter length s=π(R+X) / 2+h of the coil 40 along the spiral groove of the first guide portion 12. Then the extended width H1 of the first outlet end 41 that can be saved satisfies: The extension width H2 of the second outlet terminal 42 is also the same, and will not be described in detail. Of course, the present invention is not limited to this.

[0074] Fig.23 A structural stereogram of a magnetic assembly according to a ninth embodiment of the present invention is disclosed. Fig.24 A schematic diagram of a coil wound on a magnetic core in a magnetic component according to a ninth embodiment of the present invention is disclosed from a top view. Fig.25 A structural side view of a first magnetic core and a second magnetic core of a magnetic assembly according to a ninth embodiment of the present invention is disclosed. Fig.26A and Fig.26B The ninth embodiment of the present invention discloses a schematic diagram of a coil in a magnetic component in an axial direction. In this embodiment, the magnetic component 1e and Figures 1 to 3 The magnetic component 1 shown is similar, and the same component number represents the same component, structure and function, which will not be repeated here. In this embodiment, the magnetic component 1e includes a first magnetic core 10e, a second magnetic core 20e and four coils 40. The first magnetic core 10e and the second magnetic core 20e are connected along the axial direction J parallel to the X axis to form four pairs of winding poles 30. The four coils 40 are wound on the corresponding winding poles 30 at a spiral angle α relative to the four pairs of winding poles 30, and include a first outlet 41 and a second outlet 42. In this embodiment, along the direction parallel to the side of the first magnetic cover 11 and the second magnetic cover 21, that is, the Y-axis direction, the first outlet terminal 41 and the second outlet terminal 42 are respectively derived from the first guide portion 12a and the second guide portion 22a, wherein the first outlet terminal 41 is welded to the pad patch (not shown) on the top edge of the first magnetic cover 11, and the second outlet terminal 42 is welded to the pad patch (not shown) on the top edge of the second magnetic cover 21, so that the magnetic component 1e becomes a low-voltage and high-current coupled inductor. Of course, the present invention is not limited to this. In this embodiment, the number of turns of the coil 40 wound flat on the winding post 30 is 6 turns. The coil 40 has a line width W', and is wound on the winding post 30 according to a winding coefficient A, and the coil width W satisfies: W = W'·A. Among them, the range of the winding coefficient A is between 1 and 1.5. In some embodiments of the present invention, the range of the winding coefficient A can also be between 1.05 and 1.15. The circumference C of the inner diameter of the coil 40 for each turn. The helix angle α satisfies: The inclination angle β of the first guide portion 12a and the second guide portion 22a is greater than the helical angle α of the first outlet terminal 41 and the second outlet terminal 42. In addition, the inner diameter length S of the coil 40 disposed in the first guide portion 12a is equal to the second inner diameter length S of the coil 40 disposed in the second guide portion 22a. The size saved by the first guide portion 12a and the second guide portion 22a is

[0075] In this embodiment, since the first magnetic core 10e and the second magnetic core 20e have a maximum magnetic density limit at the back, if the assembly tolerance of the coil 40 and the first magnetic core 10e and the second magnetic core 20e is considered, the number of turns of the coil 40 will be limited within the core window formed by the first magnetic core 10e and the second magnetic core 20e. The magnetic component 1e can increase the number of turns of the coil 40 wound flatly around the winding pole 30 from 5 turns to 6 turns through the arrangement of the first guide portion 12a and the second guide portion 22a, thereby increasing the saturation current of the four-way series connection. Of course, the size and type of the first guide portion 12a and the second guide portion 22a, the number of coils 40 and the number of flat winding turns can be adjusted according to actual application requirements, and the present invention is not limited thereto.

[0076] In summary, the present invention provides a magnetic component with an improved structure. The magnetic core improves the structure at the coil outlet position (for example, a spiral, sloped or stepped groove) to ensure that the outlet position does not affect the magnetic core assembly, thereby achieving that the height of the magnetic core does not need to be designed according to the maximum coil size. In the case of overload demand, the number of coil turns can be appropriately increased to enhance the anti-saturation ability of the magnetic core, and at the same time improve the power density of the magnetic component, wherein the groove structure and the coil shape are basically matched, and the coil is not easy to be skewed during assembly, meeting the requirements of automated production, improving quality and reducing costs. The magnetic component with an improved structure of the present invention processes the inner wall of the magnetic core into a spiral, sloped or stepped groove structure, reduces the size of the magnetic core window occupied by the coil outlet, improves the utilization rate of the magnetic core window, and realizes increasing the number of coil turns or increasing the cross-sectional area of ​​the wire or reducing the height size of the magnetic core winding column. On the other hand, the inner wall of the magnetic core is processed into a groove structure similar to the spiral trajectory of the two outlet ends of the coil, which further improves the matching degree between the magnetic core and the coil, and helps to achieve efficient automated assembly of the coil and the magnetic core.

[0077] The present application may be modified in various ways by those skilled in the art at will, but all of them are within the scope of the claims of the present application.

Claims

1. A magnetic component, characterized in that: include: A first magnetic core, comprising a first magnetic cover and a first guide portion; a second magnetic core, comprising a second magnetic cover and a second guide portion, wherein the first magnetic core and the second magnetic core are butted together along an axial direction to form a winding column, wherein the winding column has a first end and a second end arranged opposite to each other along the axial direction, the first magnetic cover is located at the first end, the second magnetic cover is located at the second end, the first guide portion is adjacent to the first end and is located on the first magnetic cover, and the depth of the first magnetic cover embedded in the first magnetic cover increases from the second magnetic cover toward the first magnetic cover, the second guide portion is adjacent to the second end and is located on the second magnetic cover, and the depth of the second magnetic cover embedded in the second magnetic cover increases from the first magnetic cover toward the second magnetic cover; and A coil is wound on the winding post at a spiral angle α relative to the winding post and includes a first outlet end and a second outlet end, wherein the first outlet end is led out along the first guide portion, and the second outlet end is led out along the second guide portion.

2. A magnetic component as described in claim 1, wherein the coil is wound around the winding pole M times, M is an integer greater than or equal to 2, the circumference C of the inner diameter of the coil in each turn of the coil is greater than or equal to the circumference C' of the winding pole, and the coil increases a coil width W along the axial direction with each turn of the coil, wherein the coil has a line width W', and is wound around the winding pole according to a winding coefficient A, and the coil width W satisfies: W=W'·A. 3 . The magnetic assembly as claimed in claim 2 , wherein an inner diameter length of the coil disposed in the first guide portion is S1 , and an inner diameter length of the coil disposed in the second guide portion is S2 . The magnetic assembly as claimed in claim 3 , wherein inner diameter lengths S1 and S2 of the coil are equal. 5 . The magnetic assembly as claimed in claim 3 , wherein the first guide portion and the second guide portion are spiral grooves, and the shapes of the first guide portion and the second guide portion match the shapes of the first outlet terminal and the second outlet terminal.

6. A magnetic component as described in claim 3, wherein the first guide portion forms a first sloped groove along the first outlet end toward a side away from the first outlet end, and the second guide portion forms a second sloped groove along the second outlet end toward a side away from the second outlet end, the inclination angle β of the first guide portion and the second guide portion is greater than the spiral angle α of the first outlet end and the second outlet end, and along the axial direction, the depth D1 of the first sloped groove is greater than the protruding width H1 of the first outlet end, and the depth D2 of the second sloped groove is greater than the protruding width H2 of the second outlet end.

7. A magnetic component as described in claim 3, wherein the first guide portion forms a first step-shaped groove along the first outlet end toward a side away from the first outlet end, and the second guide portion forms a second step-shaped groove along the second outlet end toward a side away from the second outlet end, and along the axial direction, the depth D1 of the first step-shaped groove is greater than the protruding width H1 of the first outlet end, and the depth D2 of the second step-shaped groove is greater than the protruding width H2 of the second outlet end.

8. The magnetic assembly as claimed in claim 6 or 7, wherein a protruding width H1 of the first outlet terminal satisfies: The extension width H2 of the second outlet terminal satisfies: 9 . The magnetic component as claimed in claim 2 , wherein the winding coefficient A ranges from 1 to 1.

5. 10 . The magnetic component as claimed in claim 9 , wherein the winding coefficient A ranges from 1.05 to 1.

15.

11. The magnetic assembly as claimed in claim 2, wherein the helical angle α satisfies: 12 . The magnetic assembly as claimed in claim 2 , wherein the coil and the winding post have a matching gap X. 13 . The magnetic assembly as claimed in claim 2 , wherein the first outlet terminal and the second outlet terminal are respectively led out from the first guiding portion and the second guiding portion along a direction parallel to the side edges of the first magnetic cover and the second magnetic cover. 14 . The magnetic assembly as claimed in claim 1 , wherein the first magnetic core is an I-shaped magnetic core, and the winding post is disposed on a side of the second magnetic cover close to the first magnetic cover.

15. The magnetic component as described in claim 14, wherein the second magnetic core further comprises a third guide portion, which is arranged on a side of the second magnetic cover away from the first magnetic cover and is spatially arranged along the axial direction corresponding to the first guide portion, wherein the third guide portion and the first guide portion have the same structure.

16. A magnetic component as described in claim 15, wherein the magnetic component includes a first magnetic core, N second magnetic cores, N second guide portions, N third guide portions, N winding poles and N coils, N is an integer and is greater than or equal to 2, the N second magnetic cores are connected in series along the axial direction, the N winding poles are arranged in parallel along the axial direction, and the N coils are respectively wound on the N winding poles.

17. A magnetic component as described in claim 1, wherein the magnetic component includes N first guide portions, N second guide portions, N winding poles and N coils, N is an integer and is greater than or equal to 2, the N winding poles are arranged in parallel or in an array along a direction perpendicular to the axial direction, and the N coils are respectively wound on the N winding poles.

18. A magnetic component as described in claim 1 or 5, wherein the first magnetic core also includes a first boss, the first boss is adjacent to the first end and is located on the first magnetic cover, and protrudes from the first magnetic cover toward the second magnetic cover, and along the axial direction, the first boss is arranged at least relative to a portion of the second guide portion; the second magnetic core also includes a second boss, the second boss is adjacent to the second end and is located on the second magnetic cover, and protrudes from the second magnetic cover toward the first magnetic cover, and along the axial direction, the second boss is arranged at least relative to a portion of the first guide portion.

19. The magnetic assembly as claimed in claim 1, wherein the first guide portion increases a first depth D1 from the second magnetic cover toward the first magnetic cover, and the second guide portion increases a second depth D2 from the first magnetic cover toward the second magnetic cover, wherein the first depth D1 is equal to the second depth D2. 20 . The magnetic assembly as claimed in claim 1 , wherein a cross section of the winding post perpendicular to the axial direction is circular, racetrack-shaped or rounded rectangular. 21 . The magnetic component as claimed in claim 1 , wherein the magnetic component is suitable for a conventional inductor, an array inductor, a coupled inductor, a conventional transformer or an array transformer with low voltage and high current.

22. The magnetic component as claimed in claim 1, wherein the coil is a round wire or a flat wire.

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