Magnetic element

Abstract

The invention provides a magnetic element. The magnetic element comprises a magnetic core, a coil part and a winding framework, the magnetic core comprises at least one wrapping post, at least one part of the cross section of the wrapping post is a non-arc edge, and the cross section is perpendicular to the axial direction of the wrapping post. The coil part naturally and outwards forms an arched structure on the part corresponding to the non-arc-shaped edge due to the tension effect, and a first gap is formed between the arched structure and the non-arc-shaped edge. The winding framework is provided with a sleeve wall, the sleeve wall defines an internal space for accommodating the winding post, the coil part is wound on the sleeve wall, the sleeve wall comprises an arched part, a second gap is formed between the arched part and the non-arc-shaped edge, and the projection of the second gap on the cross section is located in the projection range of the first gap on the cross section; and at least one glue filling channel is formed between the sleeve wall and the non-arc-shaped edge through the second gap.

Description

Technical Field

[0001] The present disclosure relates to the technical field of switching power supplies, and particularly to a magnetic component. Background Art

[0002] With the rapid development of switching power supply technology in various application fields, more and more power products are developing towards higher efficiency, higher power density, smaller size and lower cost.

[0003] For magnetic components with high power density, the integration of an inductor and a transformer can be used to miniaturize the magnetic component. While the magnetic circuit is integrated, the skeleton structure can also be designed as an integrated structure. However, usually this integrated structure is not easy to dissipate heat due to its compactness. If the volume of the integrated structure is increased, such as adding an additional radiator, etc., although it is beneficial to heat dissipation, it will reduce the integration degree and thus reduce the power density. And under different working conditions of the magnetic component, the losses of the magnetic core and the coil will vary. Therefore, it is necessary to take into account the heat dissipation of the magnetic core and the coil under various working conditions, that is, magnetic components with high power density have higher requirements for heat dissipation.

[0004] Therefore, how to achieve better heat dissipation effect of the magnetic component without increasing the overall volume of the magnetic component and without affecting the performance of the magnetic component is an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0005] The present disclosure provides a magnetic component to solve the problems of the prior art.

[0006] According to an embodiment of the present disclosure, a magnetic component includes a magnetic core, a coil portion and a winding skeleton. The magnetic core includes a magnetic cover and a winding column. The winding column is arranged on the magnetic cover, and at least a part of the cross-section of the winding column is a non-circular arc edge, where the cross-section is perpendicular to the axial direction of the winding column. Due to the tension, a part of the coil portion corresponding to the non-circular arc edge naturally forms an arched structure outward, and a first gap is formed between the arched structure and the non-circular arc edge. The winding skeleton includes a sleeve wall that defines an internal space for accommodating the winding column. The coil portion is wound around the sleeve wall. The sleeve wall includes an arched portion. A second gap is formed between the arched portion and the non-circular arc edge. The projection of the second gap on the cross-section is within the projection range of the first gap on the cross-section. A potting channel is formed between the sleeve wall and the non-circular arc edge through the second gap.

[0007] According to another embodiment of the present disclosure, the non-circular arc edge is a straight edge or an elliptical arc edge.

[0008] According to another embodiment of the present disclosure, the maximum width T of the potting channel = A + B, where A is the assembly gap reserved between the sleeve wall and the winding column, and B is the maximum gap by which the arched portion arches outward relative to A.

[0009] According to another embodiment of the present disclosure, B is greater than or equal to 0.5 mm.

[0010] According to another embodiment of the present disclosure, the magnetic component further includes potting glue, and the potting glue passes through the potting channel at least partially, wherein the viscosity of the potting glue is less than or equal to 25 Pa·s.

[0011] According to another embodiment of the present disclosure, the shape of the arch portion is arc-shaped or triangular.

[0012] According to another embodiment of the present disclosure, the number of the arch portions is less than or equal to the number of the non-circular arc edges.

[0013] According to another embodiment of the present disclosure, the winding bobbin includes two winding retaining walls. Along the axial direction of the winding column, the two winding retaining walls are oppositely arranged on two end faces of the sleeve wall, and the sleeve wall and the two winding retaining walls jointly define a winding area for winding the coil portion.

[0014] According to another embodiment of the present disclosure, the sleeve wall includes a plurality of through holes, and the plurality of through holes communicate the internal space with the winding area.

[0015] According to another embodiment of the present disclosure, the shape of the plurality of through holes is circular or polygonal.

[0016] According to another embodiment of the present disclosure, at least one of the two winding retaining walls is provided with a potting opening.

[0017] According to another embodiment of the present disclosure, the potting opening is located in a region where the two winding retaining walls are close to at least one non-circular arc edge.

[0018] According to another embodiment of the present disclosure, the potting opening communicates with the potting channel.

[0019] According to another embodiment of the present disclosure, at least one of the two winding retaining walls has a plurality of winding openings for allowing the lead-out ends of the coil portion to pass through.

[0020] According to another embodiment of the present disclosure, the magnetic core includes a plurality of winding columns.

[0021] According to another embodiment of the present disclosure, a magnetic component includes a first magnetic core portion, a second magnetic core portion, and a third magnetic core portion. Both the first magnetic core portion and the second magnetic core portion include a magnetic cover and a winding post. The winding post is disposed on the magnetic cover, and at least a part of the cross-section of the winding post has a non-circular arc edge, where the cross-section is perpendicular to the axial direction of the winding post, and along the axial direction of the winding post, the third magnetic core portion is located between the first magnetic core portion and the second magnetic core portion. A coil portion is wound around the winding post. Due to the tension, an arched structure is naturally formed outward at the part corresponding to the non-circular arc edge of the coil portion, and a first gap is formed between the arched structure and the non-circular arc edge. The winding skeleton includes a sleeve wall that defines an internal space for accommodating the winding post. The coil portion is wound around the sleeve wall. The sleeve wall includes an arched portion, and a second gap is formed between the arched portion and the non-circular arc edge. The projection of the second gap on the cross-section is within the projection range of the first gap on the cross-section. A potting channel is formed between the sleeve wall and the non-circular arc edge through the second gap.

[0022] According to another embodiment of the present disclosure, the magnetic component is a magnetic integrated component of an inductor and a transformer. The coil portion includes an inductor coil and a transformer coil. The winding skeleton includes an inductor skeleton and a transformer skeleton. The winding post includes an inductor winding post and a transformer winding post, which are respectively disposed on the magnetic covers of the first magnetic core portion and the second magnetic core portion. The first magnetic core portion, the inductor skeleton, the inductor coil, and the third magnetic core portion constitute the inductor, and the second magnetic core portion, the transformer skeleton, the transformer coil, and the third magnetic core portion constitute the transformer.

[0023] According to another embodiment of the present disclosure, the inductor skeleton and the transformer skeleton are fixedly connected through a connecting rib, and the third magnetic core portion is disposed at the position of the connecting rib.

[0024] In summary, the present disclosure provides a magnetic component. By providing a non-circular arc edge on the cross-section of the magnetic core winding post, a first gap is formed between the arched structure naturally formed by the coil portion due to the tension and the non-circular arc edge. An arched portion is formed on the sleeve wall of the winding skeleton, so that a second gap is formed between the arched portion and the non-circular arc edge. And by the projection of the second gap on the cross-section being within the projection range of the first gap on the cross-section, the arched portion on the sleeve wall of the winding skeleton utilizes the space of the first gap, thereby creating a potting channel through the second gap between the arched portion and the non-circular arc edge, enabling the potting glue to flow smoothly and quickly into the interior of the magnetic component, and strengthening the heat dissipation capacity of the magnetic core and the coil portion. It is actually measured that the magnetic component designed by this solution can reduce the temperature by 5 - 10 °C compared with the structure of a common magnetic component of the same volume. Therefore, the magnetic component designed by this solution meets the heat dissipation requirements of high-power density magnetic components without additionally increasing the external dimensions of the product.

[0025] The above description will be described in detail in the following embodiments, and further explanations of the technical solutions of the present disclosure will be provided. Description of the Drawings

[0026] To make the above and other objects, features, and advantages of the present disclosure more obvious and understandable, the description of the drawings in the specification is as follows:

[0027] Figure 1 is a perspective view of a magnetic component according to an embodiment of the present disclosure;

[0028] Figure 2 is a schematic diagram of Figure 1 exploded view of the magnetic component;

[0029] Figure 3A is a schematic diagram of Figure 1 cross-sectional view of the magnetic component along the section line A-A;

[0030] Figure 3B is a schematic diagram of Figure 1 cross-sectional view of the magnetic component along the section line B-B;

[0031] Figure 4 is a perspective view of a magnetic component according to another embodiment of the present disclosure;

[0032] Figure 5 is a perspective view of a magnetic component according to another embodiment of the present disclosure;

[0033] Figures 6A - 6C is a perspective view of a magnetic component according to another embodiment of the present disclosure;

[0034] Figure 7 is a perspective view of a magnetic component according to another embodiment of the present disclosure;

[0035] Figure 8 is a schematic diagram of Figure 7 perspective view of the magnetic component after removing the coil part and the winding skeleton; and

[0036] Figure 9 is a perspective view of a magnetic component according to another embodiment of the present disclosure.

[0037] Among them, the description of the reference numerals is as follows:

[0038] 100, 200, 300, 400, 500, 500': magnetic components

[0039] 108: base

[0040] 110: magnetic core

[0041] 110a: first magnetic core part

[0042] 110b: second magnetic core part

[0043] 110c: third magnetic core part

[0044] 111: Magnetic cover

[0045] 111a: First magnetic cover

[0046] 111b: Second magnetic cover

[0047] 112: Winding post

[0048] 112a: Inductor winding post

[0049] 112b: Transformer winding post

[0050] 1121: Non-circular arc edge

[0051] 1122: Circular arc edge

[0052] 113: Side post

[0053] Z: Axial direction

[0054] 120: Coil part

[0055] 120a: Inductor coil

[0056] 120b: Transformer coil

[0057] 121: Arch structure

[0058] 140, 140’: Winding skeleton

[0059] 140a: Inductor skeleton

[0060] 140b: Transformer skeleton

[0061] 141: Connecting rib

[0062] 142: Sleeve wall

[0063] 1421: Arch part

[0064] 1422: Non-arch part

[0065] 143: Winding area

[0066] 143a, 143b: Through holes

[0067] 144a, 144b: Winding retaining walls

[0068] 145: Internal space

[0069] 146: Potting opening

[0070] 148a-c: Winding openings

[0071] 150a, 150b: Potting channels

[0072] 152: Potting adhesive

[0073] T: Maximum width

[0074] A: Assembly gap

[0075] B: Maximum gap

[0076] S1, S1': First gap

[0077] S2: Second gap

[0078] 500a: Inductor

[0079] 500b: Transformer

[0080] X: First direction Detailed implementation manners

[0081] Next, the technical solutions in the exemplary embodiments of the present disclosure will be clearly and completely described in conjunction with the accompanying drawings in the exemplary embodiments of the present disclosure. The exemplary embodiments described herein are only for the purpose of illustration and are not intended to limit the protection scope of the present disclosure. Therefore, it should be understood that various modifications and changes can be made to the exemplary embodiments without departing from the protection scope of the present disclosure.

[0082] In the description of the present disclosure, unless otherwise clearly defined and limited, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance; the term "plurality" means two or more; the term "and / or" includes any combination and all combinations of one or more of the associated listed items. In particular, referring to "the / this" object or "one" object also intends to represent one of the possible multiple such objects.

[0083] Unless otherwise specified or stated, terms such as "connection" and "fixation" should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, an integral connection, an electrical connection, or a signal connection; "connection" can be a direct connection or an indirect connection through an intermediate medium. For those skilled in the art, the specific meanings of the above terms in the present disclosure can be understood according to specific circumstances.

[0084] Further, in the description of the present disclosure, it should be understood that the orientation terms such as "upper", "lower", "inner", and "outer" described in the exemplary embodiments of the present disclosure are described from the angles shown in the drawings, and should not be construed as limiting the exemplary embodiments of the present disclosure. It should also be understood that in the context, when an element or feature is referred to as being "on", "under", or "inside", "outside" another element (one or more), it can not only be directly connected to another (one or more) element "on", "under", or "inside", "outside", but can also be indirectly connected to another (one or more) element "on", "under", or "inside", "outside" through an intermediate element.

[0085] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in various forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the example embodiments to those skilled in the art. Like reference numerals in the figures denote like or similar structures, and thus their detailed description will be omitted.

[0086] The inventors have learned that currently, for the heat dissipation of the magnetic core and the coil, one way is to keep the cross-sectional area of the magnetic core winding post unchanged, and increase the space between the skeleton structure and the magnetic core by setting ribs inside the skeleton structure, thereby increasing the amount of glue injected inside the magnetic component. However, such a setting will increase the overall external volume of the product because ribs are added. Another way is to eliminate the volume impact caused by adding ribs. One is to compress the winding space to offset the space increased by the ribs, but in this case, a wire with a smaller cross-sectional area needs to be selected as the coil, which will increase the heat generated by the coil part. The other is to reduce the cross-sectional area of the magnetic core winding post and increase the space between the magnetic core winding post and the skeleton structure to offset the space increased by the ribs, but this will increase the magnetic flux density of the magnetic core winding post, thereby increasing the risk of magnetic core loss and saturation.

[0087] Please also refer to Figures 1 - 2 , Figure 1 which is a perspective view of a magnetic component 100 according to an embodiment of the present disclosure. Figure 2 is a perspective view showing Figure 1 the exploded view of the magnetic component 100. The magnetic component 100 includes a magnetic core 110, a coil portion 120, and a winding skeleton 140.

[0088] The magnetic core 110 includes a magnetic cover 111 and at least one winding post 112. The winding post 112 is disposed on the magnetic cover 111. As Figure 2As shown, the magnetic cover 111 includes a first magnetic cover 111a and a second magnetic cover 111b, and the winding post 112 is disposed on the first magnetic cover 111a. In some other embodiments of this case, the winding post 112 may also be disposed on both the first magnetic cover 111a and the second magnetic cover 111b at the same time. At this time, the winding posts 112 on the first magnetic cover 111a and the second magnetic cover 111b are spliced with each other. As Figure 2 As shown, in some embodiments of this case, the magnetic core 110 further includes at least one side post 113, and the side post 113 is also disposed on the first magnetic cover 111a. In some other embodiments of this case, the side post 113 may also be disposed on both the first magnetic cover 111a and the second magnetic cover 111b at the same time. At this time, the side posts 113 on the first magnetic cover 111a and the second magnetic cover 111b are spliced with each other. As Figure 2 As shown, the magnetic core 110 includes two side posts 113, which are respectively disposed on opposite sides of the winding post 112. Along the Z cross-section perpendicular to the axial direction of the winding post 112, such as Figure 1 A-A and B-B shown, a cross-section of the winding post 112 is formed, wherein at least a part of the cross-section of the winding post 112 is a non-circular arc edge 1121, such as Figure 2 As shown, the non-circular arc edge 1121 is a straight edge.

[0089] The coil part 120 includes at least one coil. When the magnetic component 100 is an inductor, the coil part 120 includes an inductor coil. When the magnetic component 100 is a transformer, the coil part 120 includes a primary coil and a secondary coil. Among them, the coil can be a three-layer insulated litz wire or a common litz wire.

[0090] It should be noted that the non-circular arc edge 1121 refers to excluding a circular edge and an arc edge that is part of a circle, such as a straight edge or an elliptical arc edge. The purpose of such a setting is to ensure that a first gap S1 is formed between the coil part 120 and the non-circular arc edge 1121 after the coil part 120 arches outwards naturally due to the tension.

[0091] The winding skeleton 140 includes a sleeve wall 142, and the sleeve wall 142 defines an internal space 145 for accommodating the winding post 112, and the coil part 120 is wound around the sleeve wall 142. In some embodiments of the present disclosure, the winding skeleton 140 includes two winding retaining walls (144a, 144b) disposed axially opposite to each other on two end faces of the sleeve wall 142. The sleeve wall 142 and the two winding retaining walls (144a, 144b) jointly define a winding area 143 for the coil part 120 to wind.

[0092] In some embodiments of the present disclosure, a potting opening 146 is provided on at least one of the two winding retaining walls (144a, 144b).

[0093] In some embodiments of the present disclosure, at least one of the two winding retaining walls (144a, 144b) has a plurality of winding openings (148a-c) for the outgoing wire ends of the coil portion 120 to pass through.

[0094] In some embodiments of the present disclosure, the sleeve wall 142 includes a plurality of through holes (143a, 143b), and the plurality of through holes (143a, 143b) communicate the internal space 145 with the winding region 143. As Figure 2 shown, the through holes (143a, 143b) can be provided on the side wall of the sleeve wall 142 corresponding to the non-circular arc side 1121. In some embodiments of the present disclosure, the through holes (143a, 143b) can be circular or polygonal (such as triangular, square, hexagonal).

[0095] Please refer to Figures 3A - 3B at the same time Figure 3A the Figure 1 cross-sectional view of the magnetic element 100 shown along the section line A-A, Figure 3B the Figure 1 cross-sectional view of the magnetic element 100 shown along the section line B-B. In some embodiments of the present disclosure, due to the tension, a part of the coil portion 120 corresponding to the non-circular arc side 1121 of the corresponding winding post 112 naturally forms an arched structure 121 outward. A first gap S1 is formed between the arched structure 121 and the non-circular arc side 1121. The sleeve wall 142 includes an arched portion 1421, and a second gap S2 is formed between the arched portion 1421 and the non-circular arc side 1121. The projection of the second gap S2 in the cross-section is within the projection range of the first gap S1 in the cross-section. That is, the arched portion 1421 on the sleeve wall 142 of the winding skeleton 140 utilizes the space of the first gap S1. In some embodiments of this case, the shapes of the arched portion 1421 and the arched structure 121 match each other, so that the coil portion 120 is closely attached to the sleeve wall 142. It should be noted that due to manufacturing errors, the shapes of the arched portion 1421 and the arched structure 121 matching each other does not necessarily mean that their shapes are exactly the same, as long as it is ensured that their shapes are as similar as possible, so that the coil portion 120 is as closely attached to the sleeve wall 142 as possible. As Figure 2 shown, the winding post 112 can also be provided with a circular arc side 1122, and the sleeve wall 142 further includes a non-arched portion 1422. The shapes of the non-arched portion 1422 and the circular arc side 1122 match each other, further ensuring that the coil portion 120 is closely attached to the sleeve wall 142.

[0096] In some embodiments of the present disclosure, as Figure 3AAs shown, between the sleeve wall 142 and the non-circular arc-shaped edge 1121, at least one potting channel (150a, 150b) is formed by the second gap S2 formed between the arched portion 1421 and the non-circular arc-shaped edge 1121. The maximum width T of the potting channel (150a, 150b) = A + B, where A is the assembly gap reserved between the sleeve wall 142 and the winding post 112, and B is the maximum gap by which the arched portion 1421 arches outwards relative to the assembly gap A.

[0097] In some embodiments of the present disclosure, the maximum gap B is greater than or equal to 0.5 mm. The potting channels (150a, 150b) are used for at least partial passage of the potting compound 152, and the viscosity of the potting compound 152 is less than or equal to 25 Pa·s, whereby the potting compound 152 quickly flows into the interior of the product through the potting channels (150a, 150b), strengthening the heat dissipation capacity of the magnetic core 110 and the coil portion 120.

[0098] In some embodiments of the present disclosure, as Figure 3A shown, the shape of the arched portion 1421 can be triangular. At this time, the arched structure 121 of the coil portion 120 is still circular arc-shaped. However, since the non-circular arc-shaped edge 1121 is a straight edge and the length of the straight edge is relatively long, visually, the circular arc-shaped arched structure 121 is similar to a triangular edge. Therefore, the shape of the arched portion 1421 is set to be triangular. In other embodiments of this case, the shape of the arched portion 1421 can also be arc-shaped, as long as it is ensured that the projection of the second gap S2 on the cross-section is within the projection range of the first gap S1 on the cross-section. Referring to Figure 3B it can be seen that the number of arched portions 1421 of the sleeve wall 142 is less than or equal to the number of non-circular arc-shaped edges 1121 of the winding post 112. Therefore, the arched portions 1421 of the sleeve wall 142 can be flexibly set according to actual needs and the size of the first gap S1 formed between the coil portion 120 and the non-circular arc-shaped edge 1121 after the coil portion 120 naturally arches outwards due to the tension effect. As Figure 3B shown, since one of the non-circular arc-shaped edges 1121 of the winding post 112 is relatively short, the first gap S1' formed between the coil portion 120 and the non-circular arc-shaped edge 1121 after the coil portion 120 naturally arches outwards due to the tension effect is relatively small. Therefore, an arched portion 1421 may not be provided corresponding to the sleeve wall 142 here, but a non-arched portion 1422 is provided. Accordingly, the number of potting channels (150a, 150b) can also be increased by providing a plurality of non-circular arc-shaped edges 1121 on the cross-section of the winding post 112, further increasing the heat dissipation capacity of the magnetic component 100.

[0099] In some embodiments of the present disclosure, a potting opening 146 is provided on at least one of the two winding retaining walls (144a, 144b). The potting opening 146 can be located at a position on at least one non-circular arc side 1121 of the two winding retaining walls (144a, 144b) close to the winding post 112 and communicate with the potting channels (150a, 150b), whereby the potting glue 152 is introduced into the potting channels (150a, 150b) through the potting opening 146, accelerating the filling speed of the potting glue 152. In addition, a plurality of through holes (143a, 143b) enable the potting glue 152 in the potting channels (150a, 150b) to flow into the interior of the coil portion 120 through the through holes (143a, 143b), thereby enhancing the heat dissipation capacity of the coil portion 120 and balancing the heat exchange between the magnetic core 110 and the coil portion 120 under different working conditions. Therefore, the winding skeleton 140 of the present disclosure can meet the heat dissipation requirements of high-power density magnetic components without additionally increasing the external dimensions of the magnetic component 100.

[0100] Please refer to Figures 4 - 6C , wherein Figure 4 FIG. shows a perspective view of a magnetic component 200 with a dual-core winding post according to another embodiment of the present disclosure. Figure 5 FIG. shows a perspective view of a magnetic component 300 with a triple-core winding post according to another embodiment of the present disclosure. Figures 6A - 6C FIG. shows a perspective view of a magnetic component 400 with a quadruple-core winding post according to another embodiment of the present disclosure. In some embodiments of this case, the magnetic core 110 may include a plurality of winding posts 112. As Figure 4 shown, the magnetic core 110 of the magnetic component 200 has 2 winding posts 112 sequentially arranged on the magnetic cover 111 along the first direction X. As Figure 5 shown, the magnetic core 110 of the magnetic component 300 has 3 winding posts 112 sequentially arranged on the magnetic cover 111 along the first direction X. Figure 4 And Figure 5 The winding skeletons 140 and the coil portions 120 in the embodiments shown are basically the same design as those in the embodiment shown in Figures 1 - 3B , and will not be described in detail here. It can be understood that when the magnetic core 110 includes four or more winding posts 112, these winding posts 112 can all be sequentially arranged on the magnetic cover 111 along the first direction X. In other embodiments of this case, the winding posts 112 may not be sequentially arranged on the magnetic cover 111 along the first direction X. As Figures 6A - 6C shown in the embodiment, the magnetic core 110 of the magnetic component 400 has 4 winding posts 112, and the 4 winding posts 112 are respectively arranged on four sides of the magnetic cover 111. It can be understood that the winding skeleton 140 described in this case can be applied to various magnetic cores, including but not limited to similar Figure 4 , Figure 5 and Figures 6A - 6CIn the multi-winding post magnetic component shown.

[0101] Please refer to Figures 7 - 8 , Figure 7 FIG. 500 is a perspective view of a magnetic component 500 showing another embodiment of the present disclosure. Figure 8 Showing Figure 7 A perspective view of the magnetic component 500 after removing the coil portion and the winding skeleton. The magnetic component 500 includes a first magnetic core portion 110a, a second magnetic core portion 110b, and a third magnetic core portion 110c. Both the first magnetic core portion 110a and the second magnetic core portion 110b include a magnetic cover 111 and two winding posts 112. It can be understood that in other embodiments of the present case, the first magnetic core portion 110a and the second magnetic core portion 110b may also include only one winding post 112. The cross-section of the two winding posts 112 may be the same as that of the winding post 112 in the Figures 1 - 3B illustrated embodiment, and along the axial direction Z of the winding post 112, the third magnetic core portion 110c is located between the first magnetic core portion 110a and the second magnetic core portion 110b. Figures 7 - 8 The winding skeleton 140 and the coil portion 120 in the illustrated embodiment are substantially the same design as those in the Figures 1 - 3B illustrated embodiment.

[0102] In some embodiments of the present case, the magnetic component 500 is a magnetic integration component of an inductor 500a and a transformer 500b. The coil portion 120 includes an inductor coil 120a and a transformer coil 120b. The winding skeleton 140 includes an inductor skeleton 140a and a transformer skeleton 140b. The winding posts 112 include an inductor winding post 112a and a transformer winding post 112b, which are respectively arranged on the magnetic covers 111 of the first magnetic core portion 110a and the second magnetic core portion 110b. The first magnetic core portion 110a, the inductor skeleton 140a, the inductor coil 120a, and the third magnetic core portion 110c form the inductor 500a. The second magnetic core portion 110b, the transformer skeleton 140b, the transformer coil 120b, and the third magnetic core portion 110c form the transformer 500b. The inductor 500a and the transformer 500b are fixed on the base 108.

[0103] Please refer to Figure 9, which shows a perspective view of a magnetic component 500' according to another embodiment of the present disclosure. The main difference between the magnetic component 500' and the magnetic component 500 lies in the structure of the winding bobbin. The winding bobbin 140' includes an inductor bobbin 140a, a transformer bobbin 140b, and connecting ribs 141. The connecting ribs 141 connect the inductor bobbin 140a and the transformer bobbin 140b into an integral body. While the magnetic circuit is integrated, the bobbin structure can also be integrated. The inductor coil 120a and the transformer coil 120b can be automatically wound continuously. The wire groove on the connecting rib 141 between the inductor bobbin 140a and the transformer bobbin 140b can straighten and limit the coil wires during automatic winding. The third magnetic core portion 110c is disposed at a position aligned with or corresponding to the connecting rib 141.

[0104] The present disclosure provides a magnetic component. By providing a non-circular arc-shaped edge on the cross-section of the magnetic core winding post, a first gap is formed between the arched structure naturally formed by the coil portion due to the tension and the non-circular arc-shaped edge. An arched portion is formed on the sleeve wall of the winding bobbin, so that a second gap is formed between the arched portion and the non-circular arc-shaped edge. And the projection of the second gap on the cross-section is located within the projection of the first gap on the cross-section, so that the arched portion on the sleeve wall of the winding bobbin utilizes the space of the first gap. Thus, a potting channel is created by the second gap between the arched portion and the non-circular arc-shaped edge, enabling the potting compound to flow smoothly and quickly into the interior of the magnetic component, strengthening the heat dissipation capacity of the magnetic core and the coil portion. It is measured that the magnetic component designed by this solution can reduce the temperature by 5 - 10 °C compared with the structure of a common magnetic component of the same volume. Therefore, the magnetic component designed by this solution meets the heat dissipation requirements of high-power density magnetic components without additionally increasing the external dimensions of the product.

[0105] Although the present disclosure has been disclosed as above in embodiments, it is not intended to limit the present disclosure. Any person skilled in the art can make various changes and modifications without departing from the concept and scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to what is defined by the claims.

Claims

1. A magnetic component, characterized in that, Comprising: A magnetic core, including a magnetic cover and a winding post, the winding post is arranged on the magnetic cover, and at least a part of a cross-section of the winding post is a non-circular arc edge, wherein the cross-section is perpendicular to the axial direction of the winding post; A coil part, due to the tension, a bulging structure is naturally formed outward at a part corresponding to the non-circular arc edge of the coil part, and a first gap is formed between the bulging structure and the non-circular arc edge; A winding skeleton, including a sleeve wall, the sleeve wall defines an internal space for accommodating the winding post, the coil part is wound on the sleeve wall, the sleeve wall includes a bulging part, and a second gap is formed between the bulging part and the non-circular arc edge, the projection of the second gap on the cross-section is within the projection range of the first gap on the cross-section, and a potting channel is formed between the sleeve wall and the non-circular arc edge through the second gap.

2. The magnetic component according to claim 1, wherein, The non-circular arc edge is a straight edge or an elliptical arc edge.

3. The magnetic component according to claim 1, characterized in that, The maximum width T of the potting channel = A + B, where A is the assembly gap reserved between the sleeve wall and the winding post, and B is the maximum gap that the bulging part bulges outward relative to A.

4. The magnetic component according to claim 3, wherein, B is greater than or equal to 0.5 mm.

5. The magnetic component according to claim 3 or 4, characterized in that, It further includes a potting adhesive, and at least part of the potting adhesive passes through the potting channel, wherein the viscosity of the potting adhesive is less than or equal to 25 Pa·s.

6. The magnetic component according to claim 1, wherein The shape of the bulging part is arc-shaped or triangular.

7. The magnetic component according to claim 1, wherein The number of the bulging parts is less than or equal to the number of the non-circular arc edges.

8. The magnetic component according to claim 1, wherein, The winding skeleton includes two winding retaining walls, along the axial direction of the winding post, the two winding retaining walls are oppositely arranged at two end faces of the sleeve wall, and the sleeve wall and the two winding retaining walls jointly define a winding area for the coil part to be wound.

9. The magnetic component according to claim 8, wherein, The sleeve wall includes a plurality of through holes, and the plurality of through holes communicate the internal space with the winding area.

10. The magnetic component according to claim 9, characterized in that, The shapes of the plurality of through holes are circular or polygonal.

11. The magnetic component according to claim 8, wherein, At least one of the two winding retaining walls is provided with a potting opening.

12. The magnetic component according to claim 11, wherein, The potting opening is located in the area where the two winding retaining walls are close to at least one non-circular arc edge.

13. The magnetic component according to claim 11, characterized in that, The potting opening communicates with the potting channel.

14. The magnetic component according to claim 10, characterized in that, At least one of the two winding retaining walls has a plurality of winding openings for the outgoing wire ends of the coil part to pass through.

15. The magnetic component according to claim 1, wherein, The magnetic core includes a plurality of the winding posts.

16. A magnetic component, characterized in that, Comprising: A first magnetic core part, a second magnetic core part and a third magnetic core part, both the first magnetic core part and the second magnetic core part include a magnetic cover and a winding post, the winding post is arranged on the magnetic cover, at least a part of a cross-section of the winding post is a non-circular arc edge, wherein the cross-section is perpendicular to the axial direction of the winding post, and along the axial direction of the winding post, the third magnetic core part is located between the first magnetic core part and the second magnetic core part; A coil part, due to the tension, a bulging structure is naturally formed outward at a part corresponding to the non-circular arc edge of the coil part, and a first gap is formed between the bulging structure and the non-circular arc edge; A winding bobbin includes a sleeve wall that defines an inner space for accommodating the winding column. The coil portion is wound around the sleeve wall. The sleeve wall includes a cambered portion, and a second gap is formed between the cambered portion and the non-circular arc-shaped side. The projection of the second gap in the cross-section is located within the projection range of the first gap in the cross-section. A potting channel is formed between the sleeve wall and the non-circular arc-shaped side through the second gap.

17. The magnetic component according to claim 16, wherein The magnetic component is a magnetic integrated component of an inductor and a transformer. The coil portion includes an inductor coil and a transformer coil. The winding bobbin includes an inductor bobbin and a transformer bobbin. The winding column includes an inductor winding column and a transformer winding column, which are respectively arranged on the magnetic covers of the first magnetic core portion and the second magnetic core portion. The first magnetic core portion, the inductor bobbin, the inductor coil, and the third magnetic core portion constitute the inductor. The second magnetic core portion, the transformer bobbin, the transformer coil, and the third magnetic core portion constitute the transformer.

18. The magnetic component according to claim 17, wherein The inductor bobbin and the transformer bobbin are fixedly connected through a connecting rib, and the third magnetic core portion is arranged at a position corresponding to the connecting rib.

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