Magnetic assembly

Abstract

The invention relates to a magnetic assembly. The magnetic assembly comprises a magnetic core, at least one winding and at least one insulating heat conduction piece, the at least one winding is wound on the magnetic core. The insulating heat-conducting member at least partially wraps or is attached to at least one of the magnetic core and the winding, and is constructed as a heat confluence path to transfer heat energy of the magnetic core and / or the winding.

Description

Technical Field

[0001] This case concerns an electronic component, particularly a magnetic component. Background Technology

[0002] Currently, magnetic components are widely used in various technical fields, such as 5G communication equipment and automotive electronic devices. Since magnetic components have a significant impact on the overall operational efficiency of these devices, good heat dissipation capabilities in magnetic components can significantly improve the overall operational performance of the equipment.

[0003] On the other hand, to meet standards such as IP65 for waterproofing and dustproofing, heat dissipation for magnetic components in related equipment or devices is primarily achieved through passive cooling. To increase heat conduction, thermal pads are typically used to attach the magnetic component to heat sink fins. This allows heat generated by the magnetic component to be transferred to the heat sink fins via the thermal pads, and then dissipated into the environment by the heat sink fins. However, in existing processes, attaching one side of the thermal pad to the magnetic component requires manual labor and cannot be automated, resulting in long production times. Furthermore, manual attachment is prone to tolerances, which can lead to gaps when attaching the other side of the thermal pad to the heat sink fins, resulting in poor heat conduction. Moreover, due to the limited shape of the magnetic component and the thermal pad, the thermal pad cannot easily cover or tightly adhere to the surface of the magnetic component, thus hindering effective heat conduction.

[0004] Furthermore, taking common inductors as an example, magnetic components are typically assembled using a dispensing method. This method involves using adhesive to fix the wound magnetic core to the base. In this method, the gap size between each core and base, as well as the amount of adhesive dispensed each time, will vary. Therefore, gaps can easily form between the core and base after the magnetic component is bonded, resulting in poor overall thermal conductivity. In addition, the materials commonly used for the base and adhesive have poor thermal conductivity, severely impacting the heat dissipation performance of the magnetic component.

[0005] In view of this, it is necessary to develop an improved magnetic component to solve the problems faced by the existing technology. Summary of the Invention

[0006] The purpose of this invention is to provide a magnetic component in which an insulating and thermally conductive element is at least partially covered or attached to at least one of a magnetic core and a winding, thereby forming a heat conduction path to dissipate heat generated by the magnetic core and / or winding. Furthermore, the insulating and thermally conductive element can also serve as a base or overmolded component for the magnetic component, thereby improving thermal conductivity, heat dissipation efficiency, fixing strength, and reducing size, while also achieving integration, reducing manufacturing time and cost, and providing waterproof and dustproof effects.

[0007] To achieve the above objectives, this invention provides a magnetic component comprising a magnetic core, at least one winding, and at least one insulating thermally conductive element. The at least one winding is wound on the magnetic core. The insulating thermally conductive element covers or is attached to at least one of the magnetic core and the winding, and is configured as a heat conduit path to transfer heat energy from the magnetic core and / or the winding. Attached Figure Description

[0008] Figure 1A This is a schematic diagram of the structure of the magnetic component in the first embodiment of this case.

[0009] Figure 1B This is a schematic diagram of the magnetic core of the magnetic component in the first embodiment of this case.

[0010] Figure 1C This is a schematic diagram of the structure of the magnetic component in the first embodiment of this case, in which the metal plate is embedded in the insulating and heat-conducting component.

[0011] Figure 2A This is a schematic diagram of the structure of the magnetic component in the second embodiment of this case.

[0012] Figure 2B This is a schematic diagram of the connection between the magnetic component and the circuit board and heat sink in the second embodiment of this case.

[0013] Figure 3A This is a partial exploded view of the magnetic component in the third embodiment of this case.

[0014] Figure 3B This is a partial exploded view of the magnetic component of the third embodiment of this case from another perspective.

[0015] Figure 3C This is a schematic diagram of the structure of the first insulating and heat-conducting component and the second insulating and heat-conducting component of the magnetic assembly in the third embodiment of this case.

[0016] Figure 3D This is a schematic diagram of the magnetic core of the magnetic component in the third embodiment of this case.

[0017] Figure 4A This is an exploded view of the magnetic component in the fourth embodiment of this case.

[0018] Figure 4BThis is a schematic diagram of the structure of the magnetic component in the fourth embodiment of this case.

[0019] Figure 5A This is an exploded view of the magnetic component in the fifth embodiment of this case.

[0020] Figure 5B This is a schematic diagram of the structure of the magnetic component in the fifth embodiment of this case.

[0021] Figure 6A This is an exploded view of the magnetic component in the sixth embodiment of this case.

[0022] Figure 6B This is a schematic diagram of the structure of the magnetic component in the sixth embodiment of this case.

[0023] Explanation of reference numerals in the attached figures

[0024] 1a, 1b, 2, 3, 4, 5: Magnetic components

[0025] 11, 21, 31, 41: Magnetic core,

[0026] 11a: Magnetic ring,

[0027] 11b, 21d, 44d, 54d: Hollow section

[0028] 11c, 21e: Top surface,

[0029] 11d, 21f: bottom surface,

[0030] 12, 22, 32, 42, 52: Windings

[0031] 121, 221: First winding,

[0032] 121a, 122a, 123a, 221a, 222a, 32a, 42a, 52a: Endpieces

[0033] 122, 222: Second winding,

[0034] 123: Third winding

[0035] 13, 23, 33: Insulating and heat-conducting components;

[0036] 13a, 231, 43, 53: First insulating and heat-conducting component;

[0037] 13b, 232, 44, 54: Second insulating heat-conducting component; 14, 232f, 44e, 54e: Metal plate; 15: Circuit board.

[0038] 16: Heat sink,

[0039] 21a, 31a, 41a: First magnetic core component; 21b, 31b, 41b: Second magnetic core component; 21c: Magnetic frame.

[0040] 232a: Main body,

[0041] 232b: Extension

[0042] 232c: First end,

[0043] 232d: Second end,

[0044] 232e: Card slot,

[0045] 233: Third insulating and heat-conducting component

[0046] 233a: Buckle,

[0047] 311, 414: First magnetic plate,

[0048] 312, 415: Second magnetic plate

[0049] 313, 412: First side pillar,

[0050] 314, 413: Second side pillars

[0051] 33a: Bottom part,

[0052] 33b: Sidewall,

[0053] 33c, 44a, 54a: piercing,

[0054] 34: Winding frame,

[0055] 34a: Base plate,

[0056] 34b: Top plate,

[0057] 34c, 43a: winding tube,

[0058] 34d, 43e: Channels

[0059] 411: Central Pillar

[0060] 416: Circular space

[0061] 43b: Winding area

[0062] 43c: First side plate,

[0063] 43d: Second side plate

[0064] 44b, 54b: convex part,

[0065] 44c, 54c: Outer frame,

[0066] 53a: First insulating and heat-conducting part,

[0067] 53b: Second insulating and heat-conducting part

[0068] L1, L2: Axis. Detailed Implementation

[0069] Some typical embodiments embodying the features and advantages of this invention will be described in detail in the following description. It should be understood that this invention can have various variations in different ways, all of which do not depart from the scope of this invention, and the descriptions and drawings herein are for illustrative purposes only and not for limiting the invention. For example, if the following description of this invention refers to a first feature disposed on or above a second feature, it indicates that it includes embodiments where the first and second features are in direct contact, as well as embodiments where additional features may be disposed between the first and second features, so that the first and second features may not be in direct contact. Furthermore, different embodiments in this invention may use repeated reference numerals and / or reference numerals. These repeated reference numerals and / or reference numerals are for simplification and clarity purposes and are not intended to limit the relationships between the various embodiments and / or the described appearance structures. Moreover, to facilitate the description of the relationship between one component or feature and another (plural) component or feature in the drawings, spatially related terms such as "below," "below," "lower part," "above," "upper part," and similar terms may be used. In addition to the orientations shown in the accompanying drawings, spatially relevant terms are used to cover different orientations of the device in use or operation. The device may be positioned in other orientations (e.g., rotated 90 degrees or located in other orientations), and the spatially relevant terms used will be interpreted accordingly. When a component is referred to as being "connected" or "coupled" to another component, it may be directly connected to or coupled to the other component, or there may be intervening components. Although the numerical ranges and parameters of the broad scope of this application are approximate, the values ​​are stated as precisely as possible in specific examples. Furthermore, it is understood that while terms such as "first," "second," and "third" 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 used to distinguish different components; for example, a first component may be referred to as a second component. Similarly, a second component may also be referred to as a first component without departing from the scope of the embodiments. The term "and / or" in the specification includes any or all combinations of one or more of the related listed items. The term "approximately" refers to an average value within a standard error range generally accepted by those skilled in the art.

[0070] Figure 1A This is a schematic diagram of the structure of the magnetic component in the first embodiment of this case. Figure 1BThis is a schematic diagram of the magnetic core of the magnetic component in the first embodiment of this case. Figure 1C This is a schematic diagram of the structure of a magnetic component in the first embodiment of this invention, in which a metal plate is embedded in an insulating and heat-conducting component. As shown in Figures 1A, 1B, and 1C, the magnetic component 1a is, for example, but not limited to, an inductor or a choke. The magnetic component 1a includes a magnetic core 11, at least one winding 12, and an insulating and heat-conducting component 13. The magnetic core 11 includes a magnetic ring 11a, a hollow portion 11b, a top surface 11c, and a bottom surface 11d. The magnetic ring 11a has an axis L1. The hollow portion 11b extends through the center of the magnetic core 11 to define the formation of the magnetic ring 11a. The top surface 11c and the bottom surface 11d are the upper and lower opposing surfaces of the magnetic core 11. Each winding 12 is wound around the magnetic ring 11a through the hollow portion 11b of the magnetic core 11. The insulating heat-conducting element 13 has a plate-like structure and at least partially covers or attaches to at least one of the magnetic core 11 and winding 12, forming a heat flow path to transfer the heat generated by the magnetic core 11 and / or winding 12. The insulating heat-conducting element 13 can also serve as a base or overmolded component for the magnetic assembly 1a, thereby improving thermal conductivity, heat dissipation efficiency, fixing strength, and reducing volume. It also enables integration, reduces manufacturing time and cost, and achieves waterproof and dustproof effects. The axis L1 of the magnetic ring 11a is preferably perpendicular to the insulating heat-conducting element 13, but is not limited to this.

[0071] In one embodiment, the number of windings 12 is three, such as a first winding 121, a second winding 122, and a third winding 123. Furthermore, the type of windings 12 can be single-wire or double-wire; for example, the first winding 121 and the second winding 122 are single-wire coils, or the third winding 123 is a double-wire coil. It should be emphasized that the number and type of windings 12 are not limited thereto and can be adjusted according to actual application requirements. For example, in other embodiments, the number of windings 12 can be one or two, and the type of windings 12 can be flat coils. In one embodiment, the first winding 121 has two ends 121a, the second winding 122 has two ends 122a, and the third winding 123 has two ends 123a. These ends 121a, 122a, and 123a protrude from the bottom surface 11d of the magnetic core 11 and pass through and are positioned in the insulating heat-conducting element 13. Each end 121a, 122a, and 123a protrudes outward from the bottom surface of the insulating heat-conducting element 13 to form a pin, thereby allowing connection to the corresponding guide hole of the circuit board (not shown) in subsequent applications.

[0072] In this embodiment, the insulating thermally conductive element 13 is formed on the bottom surface 11d of the magnetic core 11 by insert molding, and covers or is attached to the bottom surface 11d of the magnetic core 11, and covers a portion of the winding 12. The insulating thermally conductive element 13 may be formed by insert molding of a bulk molding compound (BMC) with a high thermal conductivity. The insulating thermally conductive element 13 has a specific thermal conductivity and insulation properties, wherein the specific thermal conductivity is preferably between 1.5 W / m·K and 3.2 W / m·K, and more preferably between 2.0 W / m·K and 2.9 W / m·K, but is not limited thereto. In some embodiments, the bulk molding compound with a high thermal conductivity is, for example, but not limited to, a high thermal conductivity and pressure-resistant plastic. It should be emphasized that the constituent material of the insulating thermally conductive element 13 is not limited thereto and can be adjusted according to actual application requirements. As previously described, the insulating thermally conductive element 13 covers or is attached to the bottom surface 11d of the magnetic core 11 and partially covers the winding 12, and the insulating thermally conductive element 13 has a high thermal conductivity. Because the insulating thermally conductive element 13 has low thermal resistance, it can form a heat confluence path, thus allowing the heat energy of the magnetic core 11 and winding 12 to be conducted away from the magnetic assembly 1a via this path; that is, the heat energy of the magnetic core 11 and winding 12 can be conducted away from the system through the insulating thermally conductive element 13. It should be emphasized that the area and extent of the insulating thermally conductive element 13 covering or attaching to the magnetic core 11 and winding 12 are not limited thereto and can be adjusted according to actual application requirements. For example, in some embodiments, the insulating thermally conductive element 13 may completely cover the magnetic core 11 and winding 12, exposing only a portion of the winding 12 as a contact. Furthermore, since the insulating heat-conducting component 13 can directly position the ends of each winding 12 and form the joint after forming, it is not necessary to pre-drill holes on the base for the ends 121a, 122a, and 123a of the winding 12 to pass through, as is the case with conventional technology. This simplifies the structure and saves assembly time and cost.

[0073] In some embodiments, such as Figure 1B As shown, the magnetic component 1a also includes a metal plate 14 embedded within the insulating and heat-conducting component 13. The metal plate 14 can be, but is not limited to, an aluminum sheet or a copper sheet, and has multiple through holes for the ends of the corresponding windings 12 to pass through. The metal plate 14 improves the temperature uniformity and equivalent thermal conductivity of the insulating and heat-conducting component 13, further reducing the thermal resistance of the heat flow path and enhancing the heat dissipation efficiency of the magnetic component 1a.

[0074] Figure 2A This is a schematic diagram of the structure of the magnetic component in the second embodiment of this case. Figure 2BThis is a schematic diagram of the connection between the magnetic component and the circuit board and heat sink in the second embodiment of this case. As shown in Figures 2A and 2B, the structure of the magnetic core 11 and winding 12 of the magnetic component 1b in this embodiment is the same as that of the magnetic core 11 and winding 12 of the magnetic component 1a in the first embodiment, and therefore will not be described again here. In this embodiment, unlike the magnetic component 1a in the first embodiment, the magnetic component 1b includes two insulating heat-conducting elements 13, including a first insulating heat-conducting element 13a and a second insulating heat-conducting element 13b. Both the first insulating heat-conducting element 13a and the second insulating heat-conducting element 13b are plate-shaped structures. The first insulating heat-conducting element 13a covers or is attached to the bottom surface 11d of the magnetic core 11 and part of the winding 12. The second insulating heat-conducting element 13b covers or is attached to the top surface 11c of the magnetic core 11 and part of the winding 12. In this embodiment, the materials and forming methods of the first insulating heat-conducting element 13a and the second insulating heat-conducting element 13b are similar to those in the first embodiment, and will not be described again here. In some embodiments, the ends 121a, 122a, and 123a of the magnetic component 1b can pass through and connect to the corresponding through holes of the circuit board 15. The first insulating thermally conductive element 13a of the magnetic component 1b is attached to the circuit board 15, and the second insulating thermally conductive element 13b of the magnetic component 1b is attached to a heat sink 16. Since the first insulating thermally conductive element 13a and the second insulating thermally conductive element 13b have high thermal conductivity, they can respectively form heat flow paths, so that the heat energy of the magnetic core 11 and the winding 12 can be conducted away from the magnetic component 1b through these paths. That is, the heat energy of the magnetic core 11 and the winding 12 can be conducted to the circuit board 15 through the first insulating thermally conductive element 13a, and then the heat energy is conducted away from the system through the circuit board 15. The heat energy of the magnetic core 11 and the winding 12 can be conducted to the heat sink 16 through the second insulating thermally conductive element 13b, and then the heat energy is conducted away from the system through the heat sink 16 or a heat sink (not shown) further attached to the heat sink 16.

[0075] Figure 3A This is a partial exploded view of the magnetic component in the third embodiment of this case. Figure 3B This is a partial exploded view of the magnetic component of the third embodiment of this case from another perspective. Figure 3C This is a schematic diagram of the structure of the first insulating and heat-conducting component and the second insulating and heat-conducting component of the magnetic assembly in the third embodiment of this case. Figure 3DThis is a schematic diagram of the magnetic core of the magnetic assembly according to the third embodiment of this case. As shown in Figures 3A, 3B, 3C and 3D, the magnetic assembly 2 is, for example, but not limited to, a transformer. The magnetic assembly 2 includes a magnetic core 21, at least one winding 22 and at least one insulating and heat-conducting element 23. In this embodiment, the magnetic core 21 includes a first magnetic core component 21a, a second magnetic core component 21b, a hollow portion 21d, a top surface 21e and a bottom surface 21f. The first magnetic core component 21a and the second magnetic core component 21b are coupled to define a magnetic frame 21c, wherein the first magnetic core component 21a and the second magnetic core component 21b may be UU-type, UI-type, or EE-type magnetic cores, but are not limited thereto. The hollow portion 21d is located in the middle region of the magnetic core 21 and extends through the magnetic frame 21c, the magnetic frame 21c having an axis L2. The top surface 21e and the bottom surface 21f are the upper and lower opposing surfaces of the magnetic core 21. In this embodiment, the winding 22 includes a first winding 221 and a second winding 222, which are respectively configured as the primary winding and secondary winding of a transformer. In one embodiment, the winding 22 is a flat coil, but this is not a limitation. It should be emphasized that the number and type of winding 22 are not limited thereto and can be adjusted according to actual application requirements. Each winding 22 is wound on the magnetic frame 21c through the hollow portion 21d of the magnetic core 21. The first winding 221 has two ends 221a, and the second winding 222 has two ends 222a. Each end 221a and 222a protrudes from the bottom surface 21f of the magnetic core 21, passes through and is positioned in the insulating heat-conducting component 23, and each end 221a and 222a protrudes outward from the bottom surface of the insulating heat-conducting component 23 to form a pin for subsequent connection with the corresponding guide hole of the circuit board (not shown).

[0076] In this embodiment, the insulating heat-conducting element 23 includes a first insulating heat-conducting element 231 and a second insulating heat-conducting element 232. The first insulating heat-conducting element 231 has a plate-like structure. The second insulating heat-conducting element 232 includes a main body 232a and two extensions 232b, and the two extensions 232b extend outward from the outer surfaces of the bottom sides of the main body 232a and are connected to the first insulating heat-conducting element 231. The first insulating heat-conducting element 231 and the second insulating heat-conducting element 232 are arranged perpendicularly to each other. The first insulating heat-conducting element 231 covers the winding 22, and the first end 232c of the second insulating heat-conducting element 232 is connected to the first insulating heat-conducting element 231 and disposed in the hollow portion 21d of the magnetic core 21, and is disposed between the first winding 221 and the second winding 222. In one embodiment, the two extensions 232b of the second insulating heat-conducting element 232 are attached to the bottom surface 21f of the magnetic core 21. However, the attachment range between the second insulating heat-conducting element 232 and the magnetic core 21 is not limited to this. In one embodiment, the top surface of the two extensions 232b and the outer surfaces on both sides of the main body 232a of the second insulating heat-conducting element 232 can also be attached to the bottom surface 21f and the inner surface of the magnetic core 21, respectively. Thus, the magnetic assembly 2 can conduct heat energy from the winding 22 and the magnetic core 21 through the heat flow path formed by the first insulating heat-conducting element 231 and the second insulating heat-conducting element 232. In one embodiment, it is preferable that the axis L2 of the magnetic frame 21c is perpendicular to the first insulating heat-conducting element 231, but this is not a limitation.

[0077] In this embodiment, the magnetic component 2 further includes a third insulating heat-conducting element 233. The third insulating heat-conducting element 233 has a plate-like structure, but is not limited thereto. The second end 232d of the second insulating heat-conducting element 232 is connected to the third insulating heat-conducting element 233, and the second insulating heat-conducting element 232 and the third insulating heat-conducting element 233 are arranged perpendicularly to each other. The first insulating heat-conducting element 231 and the second insulating heat-conducting element 232 may be, but are not limited to, integrally formed structures, that is, both are formed simultaneously by embedded injection molding. In this embodiment, the second end 232d of the second insulating heat-conducting element 232 has at least one slot 232e, and the third insulating heat-conducting element 233 has at least one buckle 233a, wherein the second insulating heat-conducting element 232 and the third insulating heat-conducting element 233 are connected by the slot 232e and the buckle 233a engaging with each other. Alternatively, the second end 232d of the second insulating heat-conducting element 232 has at least one snap-fit, and the third insulating heat-conducting element 233 has at least one slot, wherein the second insulating heat-conducting element 232 and the third insulating heat-conducting element 233 are connected to each other by the slot and the snap-fit. In some embodiments, the second insulating heat-conducting element 232 and the third insulating heat-conducting element 233 may also be a single integrally formed component, or the first insulating heat-conducting element 231, the second insulating heat-conducting element 232, and the third insulating heat-conducting element 233 may be a single integrally formed component. In one embodiment, the third insulating heat-conducting element 233 does not contact the winding 22, but this is not a limitation; in some embodiments, the third insulating heat-conducting element 233 may be attached to or at least partially cover the winding 22. Therefore, the magnetic component 2 can conduct heat energy from the winding 22 and the magnetic core 21 through the heat flow path formed by the first insulating heat-conducting component 231, the second insulating heat-conducting component 232, and the third insulating heat-conducting component 233, respectively. In addition, the insulating heat-conducting component 23 can also serve as the base of the magnetic component 2, thereby improving thermal conductivity, heat dissipation efficiency, increasing fixing strength, reducing size, and enabling integration, reducing manufacturing time and cost, as well as achieving waterproof and dustproof effects.

[0078] In some embodiments, the magnetic component 2 includes a metal plate 232f or a magnetic plate embedded within the second insulating heat-conducting component 232. The metal plate 232f may be, but is not limited to, an aluminum sheet or a copper sheet, and the magnetic plate may be made of the same material as the magnetic core 21. Since the second insulating heat-conducting component 232 is disposed between the first winding 221 and the second winding 222, the covered metal plate 232f or magnetic plate is positioned between the first winding 221 and the second winding 222. This allows the metal plate 232f to improve temperature uniformity and increase the equivalent thermal conductivity, thereby improving heat dissipation efficiency. Furthermore, the magnetic plate can be used to increase or adjust the leakage inductance of the magnetic component 2. In other embodiments, the magnetic component 2 includes multiple metal plates, which are respectively embedded in the first insulating heat-conducting component 231, the second insulating heat-conducting component 232 and / or the third insulating heat-conducting component 233, thereby improving the overall temperature uniformity and equivalent thermal conductivity of the insulating heat-conducting component 23, and thus improving the heat dissipation performance of the magnetic component 2.

[0079] Figure 4A This is an exploded view of the magnetic component in the fourth embodiment of this case. Figure 4BThis is a schematic diagram of the structure of the magnetic component according to the fourth embodiment of this case. As shown in Figures 4A and 4B, the magnetic component 3 is, for example, but not limited to, an inductor or a choke. The magnetic component 3 includes a magnetic core 31, at least one winding 32, at least one insulating and heat-conducting element 33, and a winding frame 34. The magnetic core 31 includes a first magnetic core component 31a and a second magnetic core component 31b. The first magnetic core component 31a and the second magnetic core component 31b are coupled together and include a first magnetic plate 311, a second magnetic plate 312, a first side post 313, and a second side post 314. The two ends of the first side post 313 and the second side post 314 are respectively connected to the first magnetic plate 311 and the second magnetic plate 312, and the first side post 313 and the second side post 314 are separated from each other and arranged in parallel. In one embodiment, the first magnetic core component 31a and the second magnetic core component 31b are UU-type magnetic cores or UI-type magnetic cores, and are not limited thereto. The winding frame 34 includes a base plate 34a, a top plate 34b, two winding tubes 34c, and two channels 34d, wherein the winding frame 34 is a single integrally formed component. Each winding tube 34c has its two ends connected to the base plate 34a and the top plate 34b respectively, and they are separated from each other and arranged parallel to each other. The two channels 34d respectively penetrate the base plate 34a, the top plate 34b, and the corresponding winding tube 34c. In this embodiment, there is one winding 32, which forms two coils and is wound around the winding area on the outer periphery of the two winding tubes 34c, and has two ends 32a, which extend downwards and protrude along the periphery of the base plate 34a of the winding frame 34. In other embodiments, there are multiple windings 32, which each form a coil and are fitted onto the winding area of ​​the corresponding winding tube 34c of the two winding tubes 34c. In this embodiment, the first side post 313 and the second side post 314 of the magnetic core 31 are respectively inserted into the corresponding channels 34d of the two winding tubes 34c. The insulating heat-conducting component 33 includes a base 33a, two side walls 33b, and a through hole 33c. The two side walls 33b are respectively connected to the two sides of the top surface of the base 33a and protrude upwards, and the top surface of the base 33a is attached to the lower surface of the first magnetic plate 311. In this embodiment, the length between the two side walls 33b is slightly greater than the length of the first magnetic plate 311, so that when the insulating heat-conducting component 33 is formed, the two side walls 33b cover and connect to the two sides and part of the upper surface of the first magnetic plate 311. However, this is not a limitation. In some embodiments, the length between the two side walls 33b may also be the same as the length of the first magnetic plate 311, so that the two side walls 33b are attached to the two sides of the first magnetic plate 311. The perforation 33c penetrates the base member 33a and corresponds to the two ends 32a of the winding 32, so that the two ends 32a of the winding 32 can pass through and the aforementioned ends 32a protrude from the bottom surface of the base member 33a, thereby forming a lead. In addition, the two ends 32a of the winding 32 are partially covered by the insulating heat-conducting member 33, so that the two ends 32a are positioned on the insulating heat-conducting member 33.Therefore, by setting the insulating heat-conducting component 33, a heat flow path can be formed to conduct heat energy from the magnetic core 31 and the winding 32, and at the same time, the two ends 32a of the winding 32 can be fixed to form a connector. In addition, the insulating heat-conducting component 33 can also serve as a base for the magnetic component 3, thereby improving thermal conductivity, heat dissipation efficiency, fixing strength, reducing size, and enabling integration, reducing manufacturing time and cost, as well as achieving waterproof and dustproof effects.

[0080] In this embodiment, the magnetic component 3 further includes a metal plate (not shown) embedded in the bottom part 33a of the insulating and heat-conducting component 33. The metal plate (not shown) may be, but is not limited to, an aluminum sheet or a copper sheet, thereby improving the overall temperature uniformity and equivalent thermal conductivity of the insulating and heat-conducting component 33, and thus improving the heat dissipation performance of the magnetic component 3.

[0081] Figure 5A This is an exploded view of the magnetic component in the fifth embodiment of this case. Figure 5B This is a schematic diagram of the structure of the magnetic component according to the fifth embodiment of this case. As shown in Figures 5A and 5B, the magnetic component 4 is, for example, but not limited to, an inductor or a choke. The magnetic component 4 includes a magnetic core 41, a winding 42, a first insulating heat-conducting element 43, and a second insulating heat-conducting element 44. The magnetic core 41 includes a first magnetic core component 41a and a second magnetic core component 41b. The first magnetic core component 41a and the second magnetic core component 41b are coupled together and include a central post 411, a first side post 412, a second side post 413, a first magnetic plate 414, a second magnetic plate 415, and an annular space 416. The two ends of the central post 411 of the magnetic core 41 are respectively connected to the first magnetic plate 414 and the second magnetic plate 415, and are located between the first side post 412 and the second side post 413. The first side post 412 and the second side post 413 are respectively connected to the first magnetic plate 414 and the second magnetic plate 415 at both ends, and the first side post 412 and the second side post 413 are disposed on two opposite sides of the first magnetic plate 414 and the second magnetic plate 415. An annular space 416 is defined between the central post 411, the first side post 412 and the second side post 413. In one embodiment, the first magnetic core component 41a and the second magnetic core component 41b are EE-type magnetic cores, but are not limited thereto.

[0082] In this embodiment, the first insulating heat-conducting component 43 is structured as a winding frame and includes a winding tube 43a, a winding area 43b, a first side plate 43c, a second side plate 43d, and a channel 43e. The winding area 43b is disposed on the outer periphery of the winding tube 43a, and the first side plate 43c and the second side plate 43d are connected and disposed at both ends of the winding tube 43a. The channel 43e passes through the center of the winding tube 43a. The first insulating heat-conducting component 43 is formed in the annular space 416 of the magnetic core 41 by an injection molding process, wherein the central post 411 of the magnetic core 41 is accommodated in the channel 43e of the first insulating heat-conducting component 43, and the first insulating heat-conducting component 43 covers and is attached to the outer peripheral surface of the central post 411. The winding 42 is wound on the winding area 43b of the first insulating heat-conducting component 43 and has two ends 42a. The second insulating heat-conducting element 44 has a plate-like structure and includes two through holes 44a, four protrusions 44b, an outer frame 44c, and a hollow portion 44d. The two through holes 44a pass through the second insulating heat-conducting element 44 and correspond to the two ends 42a of the winding 42. The two ends 42a of the winding 42 pass through the through holes 44a and are disposed thereto form leads. The outer frame 44c surrounds the hollow portion 44d.

[0083] In this embodiment, the first insulating heat-conducting element 43 is disposed above the second insulating heat-conducting element 44 and opposite to the hollow portion 44d. The second insulating heat-conducting element 44 is formed by an injection molding process and covers or attaches to the bottom surface of the magnetic core 41. The four protrusions 44b of the second insulating heat-conducting element 44 are connected to the periphery of the first side plate 43c and the second side plate 43d of the first insulating heat-conducting element 43. In one embodiment, the second insulating heat-conducting element 44 and the first insulating heat-conducting element 43 are integrally formed as a single component. The portion of the second insulating heat-conducting element 44 that covers and attaches to the two ends 42a of the winding 42 at its through-hole 44a allows the winding 42 to be thermally coupled to the second insulating heat-conducting element 44 through the two ends 42a. Thus, by setting the first insulating heat-conducting element 43 and the second insulating heat-conducting element 44, a heat flow path can be formed to conduct heat energy from the magnetic core 41 and the winding 42, and at the same time, the two ends 42a of the winding 42 can be fixed to form a connector. In addition, the first insulating heat-conducting element 43 can serve as a winding frame, and the second insulating heat-conducting element 44 can serve as a base for the magnetic component 4, thereby improving thermal conductivity, heat dissipation efficiency, fixing strength, reducing size, and enabling integration, reducing manufacturing time and cost, as well as achieving waterproof and dustproof effects.

[0084] In some embodiments, the magnetic component 4 further includes a metal plate 44e embedded in the outer frame 44c of the second insulating heat-conducting component 44, thereby improving the overall temperature uniformity and equivalent thermal conductivity of the second insulating heat-conducting component 44, and thus enhancing the heat dissipation performance of the magnetic component 4. In some embodiments, the second insulating heat-conducting component 44 may also be structured as a circuit board and does not cover the aforementioned metal plate 44e, but this is not a limitation.

[0085] Figure 6A This is an exploded view of the magnetic component in the sixth embodiment of this case. Figure 6B This is a schematic diagram of the structure of the magnetic component according to the sixth embodiment of this case. As shown in Figures 6A and 6B, the magnetic component 5 is, for example, but not limited to, an inductor or a choke. The magnetic component 5 includes a magnetic core 41, a winding 52, a first insulating heat-conducting element 53, and a second insulating heat-conducting element 54. The structure and function of the magnetic core 41, the winding 52, and the second insulating heat-conducting element 54 are similar to those of the magnetic core 41, the winding 42, and the second insulating heat-conducting element 44 in the fifth embodiment, and therefore will not be described again here. In this embodiment, unlike the first insulating heat-conducting element 43 of the magnetic component 4 in the fifth embodiment, the first insulating heat-conducting element 53 of the magnetic component 5 includes a first insulating heat-conducting portion 53a and a second insulating heat-conducting portion 53b. The first insulating heat-conducting portion 53a is generally in the form of two semi-annular structures, and the two semi-annular structures are symmetrical about the axis of the central column 411 and formed in the annular space 416 of the magnetic core 41. The first insulating and heat-conducting part 53a covers and is attached to the inner surface of the annular space 416 of the magnetic core 41 and at least part of the outer peripheral surface of the winding 52. The second insulating and heat-conducting part 53b has an annular structure and is sandwiched between the outer peripheral surface of the central column 411 and the inner peripheral surface of the winding 52. The inner peripheral surface of the second insulating and heat-conducting part 53b is attached to the outer peripheral surface of the central column 411 of the magnetic core 41, and the outer peripheral surface of the second insulating and heat-conducting part 53b is attached to the inner peripheral surface of the winding 52. The structure of the second insulating and heat-conducting part 53b is a winding frame, wherein the winding 52 is wound around the central column 411 on the outer periphery of the second insulating and heat-conducting part 53b and has two ends 52a. The two ends 52a penetrate and are positioned in the first insulating and heat-conducting part 53a, and protrude outward from the bottom surface of the first insulating and heat-conducting part 53a to form two joints. In other embodiments, the first insulating and heat-conducting portion 53a may also be a structure that completely covers the outer annular surface of the winding 52.

[0086] In this embodiment, the axis of the central column 411 is parallel to the second insulating heat-conducting element 54. The second insulating heat-conducting element 54 has a plate-like structure and has two through holes 54a, four protrusions 54b, an outer frame 54c, and a hollow portion 54d. The first insulating heat-conducting element 53 is disposed above the second insulating heat-conducting element 54 and is disposed opposite to the hollow portion 54d. The second insulating heat-conducting element 54 is formed by an embedded injection molding process and covers and attaches to the bottom surface of the magnetic core 41, wherein the four protrusions 54b of the second insulating heat-conducting element 54 are connected to the periphery of the first insulating heat-conducting element 53. In one embodiment, the second insulating heat-conducting element 54 and the first insulating heat-conducting element 53 are integrally formed as a single component, but this is not a limitation. The portion of the second insulating heat-conducting element 54 that covers and attaches to the two ends 52a of the winding 52 at its through holes 54a allows the winding 52 to be thermally coupled to the second insulating heat-conducting element 54 through the two ends 52a. Thus, by setting the first insulating heat-conducting element 53 and the second insulating heat-conducting element 54, a heat flow path can be formed to conduct the heat energy of the magnetic core 41 and the winding 52, and at the same time, the two ends 52a of the winding 52 can be fixed to form a connector. In addition, the second insulating heat-conducting part 53b can serve as a winding frame, and the second insulating heat-conducting element 54 can serve as a base for the magnetic component 5. This can improve thermal conductivity, improve heat dissipation efficiency, increase fixing strength, reduce volume, and also enable integration, reduce manufacturing time and cost, as well as achieve waterproof and dustproof effects.

[0087] In some embodiments, the magnetic component 5 further includes a metal plate 54e embedded in the outer frame 54c of the second insulating heat-conducting component 54, thereby improving the overall temperature uniformity and equivalent thermal conductivity of the second insulating heat-conducting component 54, and thus enhancing the heat dissipation performance of the magnetic component 5. In some embodiments, the second insulating heat-conducting component 54 may be configured as a circuit board and may not cover the aforementioned metal plate 54e.

[0088] In some embodiments, the aforementioned insulating and thermally conductive element is formed by embedding injection molding with at least a portion of the magnetic core and winding using a bulk molding compound (BMC) having a specific thermal conductivity between 1.5 W / m·k and 3.0 W / m·k. However, the molding material of the insulating and thermally conductive element is not limited to this and can be varied according to actual needs.

[0089] In summary, this invention provides a magnetic component in which an insulating and thermally conductive element is at least partially covered or attached to at least one of the magnetic core and the winding, thereby forming a heat conduction path so that the heat generated by the magnetic core and / or the winding can be dissipated. Furthermore, the insulating and thermally conductive element can also serve as a base or overmolded component for the magnetic component, thereby not only improving thermal conductivity, heat dissipation efficiency, and fixing strength, and reducing volume, but also achieving integration, reducing manufacturing time and cost, and achieving waterproof and dustproof effects.

[0090] This case may be modified in various ways by those skilled in the art, but none of them shall deviate from the scope of protection sought by the appended patent application.

Claims

1. A magnetic component, wherein, Include: One magnetic core; At least one winding is wound on the magnetic core; and At least one insulating thermally conductive element is at least partially covered or attached to at least one of the magnetic core and the at least one winding, and is configured as a heat flow path to transfer the heat energy of the magnetic core or the at least one winding.

2. The magnetic component according to claim 1, wherein, The magnetic component can be an inductor, a choke, or a transformer.

3. The magnetic component according to claim 1, wherein, The magnetic core includes a magnetic ring, a hollow portion, a top surface, and a bottom surface. The hollow portion passes through the magnetic ring, and each winding is wound around the magnetic ring through the hollow portion and has two ends. Each end protrudes from the bottom surface of the magnetic core. An insulating and heat-conducting element covers or is attached to the bottom surface of the magnetic core, and each end passes through and is positioned in the insulating and heat-conducting element. Each end protrudes outward from the bottom surface of the insulating and heat-conducting element to form a connector. An axis of the magnetic ring is perpendicular to the insulating and heat-conducting element.

4. The magnetic component according to claim 1, wherein, The magnetic core includes a magnetic ring, a hollow portion, a top surface, and a bottom surface. The hollow portion passes through the magnetic ring. Each winding is wound around the magnetic ring through the hollow portion and has two ends. Each end protrudes from the bottom surface of the magnetic core. The at least one insulating heat-conducting element includes a first insulating heat-conducting element and a second insulating heat-conducting element. The first insulating heat-conducting element at least partially covers or is attached to the bottom surface of the magnetic core and a portion of the winding. The second insulating heat-conducting element at least partially covers or is attached to the top surface of the magnetic core and a portion of the winding. Each end passes through and is positioned in the first insulating heat-conducting element and protrudes outward from the bottom surface of the first insulating heat-conducting element to form a connector. An axis of the magnetic ring is perpendicular to the insulating heat-conducting element.

5. The magnetic component according to claim 3 or 4, wherein, The magnetic component also includes at least one metal plate embedded within the at least one insulating and heat-conducting component.

6. The magnetic component according to claim 1, wherein, The at least one winding includes a first winding and a second winding. The magnetic core includes a first magnetic core component and a second magnetic core component. The first magnetic core component and the second magnetic core component are coupled to define a magnetic frame, a hollow portion, a top surface, and a bottom surface. The hollow portion passes through the magnetic frame. Each winding is wound around the magnetic frame through the hollow portion and has two ends. Each end protrudes from the bottom surface of the magnetic core. The at least one insulating thermally conductive element includes a first insulating thermally conductive element and a second insulating thermally conductive element. The first insulating thermally conductive element at least partially covers the at least one winding. The second insulating thermally conductive element is disposed in the hollow portion and attached to the bottom surface of the magnetic core, and is disposed between the first winding and the second winding. A first end of the second insulating thermally conductive element is connected to the first insulating thermally conductive element. Each end penetrates and is positioned in the first insulating thermally conductive element, and protrudes outward from the bottom surface of the first insulating thermally conductive element to form a connector.

7. The magnetic component according to claim 6, wherein, The magnetic component includes at least one metal plate or one magnetic plate, which is embedded in the second insulating and heat-conducting component, wherein the at least one winding includes at least one first winding and at least one second winding.

8. The magnetic component according to claim 6, wherein, The insulating and heat-conducting component also includes a third insulating and heat-conducting component, which is disposed on the top surface of the magnetic core and connected to a second end of the second insulating and heat-conducting component.

9. The magnetic component according to claim 8, wherein, The third insulating and thermally conductive element is at least partially covered or attached to the at least one winding.

10. The magnetic component according to claim 1, wherein, The magnetic component also includes a winding frame, which includes at least one winding tube and at least one channel, each channel passing through the corresponding winding tube. The at least one winding is wound around a winding area of ​​the at least one winding tube. The magnetic core partially passes through the at least one channel of the winding frame and is partially exposed to the winding frame, having a top surface and a bottom surface. Each winding has two ends that protrude from the bottom surface of the magnetic core. The insulating heat-conducting element at least partially covers or is attached to the bottom surface of the magnetic core. The two ends pass through and are positioned on the insulating heat-conducting element, and protrude outward from the bottom surface of the insulating heat-conducting element to form two pins.

11. The magnetic component according to claim 1, wherein, The magnetic core includes a first magnetic core component and a second magnetic core component. The first magnetic core component and the second magnetic core component are coupled together and include a central post, a first side post, a second side post, a first plate, a second plate, and an annular space. The two ends of the central post are respectively connected to the first plate and the second plate. The two ends of the first side post are respectively connected to the first plate and the second plate. The two ends of the second side post are respectively connected to the first plate and the second plate. The first plate and the second side post are respectively connected to the first plate and the second plate. The two plates are parallel, the central column is located between the first side column and the second side column, and the central column, the first side column and the second side column define the annular space. The at least one insulating heat-conducting element includes a first insulating heat-conducting element, the first insulating heat-conducting element is structured as a winding frame and is disposed in the annular space. The inner circumference of the first insulating heat-conducting element covers and is attached to the outer circumferential surface of the central column of the magnetic core. The at least one winding is wound on a winding area of ​​the first insulating heat-conducting element.

12. The magnetic component according to claim 1, wherein, The magnetic core includes a first magnetic core component and a second magnetic core component, which are coupled together. The first magnetic core component includes a central post, a first side post, a second side post, a first plate, a second plate, and an annular space. The two ends of the central post are connected to the first plate and the second plate, respectively. The two ends of the first side post are also connected to the first plate and the second plate, respectively. The first plate and the second plate are parallel to each other, and the central post is located between the first side post and the second side post. The annular space is defined by the central column, the first side column, and the second side column. The at least one winding is wound around the central column. The at least one insulating and heat-conducting element includes a first insulating and heat-conducting element, which includes a first insulating and heat-conducting portion and a second insulating and heat-conducting portion. The first insulating and heat-conducting portion is formed in the annular space and is attached to the inner surface of the annular space and at least a portion of the outer peripheral surface of the winding. The second insulating and heat-conducting portion is disposed in the annular space and is attached to the inner peripheral surface of the at least one winding and the outer peripheral surface of the central column of the magnetic core.

13. The magnetic component according to claim 11 or 12, wherein, The at least one insulating thermal conductive element further includes a second insulating thermal conductive element, which covers or is attached to a bottom surface of the magnetic core. Each winding has two ends that pass through and are positioned in the second insulating thermal conductive element, and the two ends protrude outward from a bottom surface of the second insulating thermal conductive element to form two joints. An axis of the central column is parallel to the second insulating thermal conductive element.

14. The magnetic component according to claim 13, wherein, The first insulating and heat-conducting component and the second insulating and heat-conducting component are integrally formed single components.

15. The magnetic component according to any one of claims 1 to 4 and 6 to 12, wherein, The insulating thermally conductive component has a specific thermal conductivity that is between 1.5 W / m·K and 3.2 W / m·K.

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