Magnetic element

Abstract

A magnetic element includes a magnetic body, a first winding, a second winding, and a magnetic filler. The first winding is disposed in the magnetic body. A first end and a second end of the first winding extend toward a first side and a second side of the magnetic body, respectively. The second winding is disposed in the magnetic body. A third end and a fourth end of the second winding extend toward the first side of the magnetic body. The first winding partially covers the second winding. The magnetic filler is filled between the first winding and the second winding.

Description

Technical Field

[0001] This invention relates to a magnetic element, and more particularly to a magnetic element with controllable leakage inductance. Background Technology

[0002] Inductors are important magnetic components used for filtering, energy storage, and voltage regulation. Inductors are present in most circuits. Generally, electromagnetic coupling and voltage stability are closely related to the leakage inductance of an inductor. In other words, leakage inductance determines the quality of energy coupling. Therefore, controlling the leakage inductance of an inductor becomes a major design challenge. Summary of the Invention

[0003] The present invention provides a magnetic element with controllable leakage inductance to solve the above-mentioned problems.

[0004] According to one embodiment, the magnetic element of the present invention includes a magnetic body, a first winding, a second winding, and a magnetic filler. The first winding is disposed within the magnetic body. A first end and a second end of the first winding extend toward a first side and a second side of the magnetic body, respectively. The second winding is disposed within the magnetic body. A third end and a fourth end of the second winding extend toward the first side of the magnetic body. The first winding partially covers the second winding. The magnetic filler fills the space between the first winding and the second winding.

[0005] In one embodiment, the first winding has fewer than one turn.

[0006] In one embodiment, the second winding has fewer than or equal to one turn.

[0007] In one embodiment, the first side is opposite to the second side.

[0008] In one embodiment, two isolation trenches are formed on the first side and a third side of the magnetic body, located between the first winding and the second winding, and penetrating the magnetic body; the third side is connected between the first side and the second side.

[0009] In one embodiment, each isolation trench includes a gap, and the magnetic filler is filled in the gap.

[0010] In one embodiment, the cross-section of the gap is triangular.

[0011] In one embodiment, the first end extends from a corner of the first winding, such that the magnetic body forms a triangular region adjacent to the first winding.

[0012] In one embodiment, the third end extends horizontally to form an electrode, and the fourth end extends vertically to form another electrode.

[0013] In one embodiment, the first winding and the second winding are covered by an insulating layer; electrodes are formed on the first end, the second end, the third end and the fourth end exposed outside the insulating layer.

[0014] In one embodiment, the cross-section of the first winding is larger than the cross-section of the second winding.

[0015] According to another embodiment, the magnetic element of the present invention includes a magnetic body, a plurality of first windings, a plurality of second windings, and a plurality of magnetic fillers. The plurality of first windings are disposed within the magnetic body and arranged at intervals. A first end and a second end of each first winding extend toward a first side and a second side of the magnetic body, respectively. The plurality of second windings are disposed within the magnetic body and arranged at intervals. A third end and a fourth end of each second winding extend toward the first side of the magnetic body. The plurality of first windings partially cover the plurality of second windings. The plurality of magnetic fillers fill the space between the plurality of first windings and the plurality of second windings.

[0016] In one embodiment, two isolation trenches are formed on the first side and a third side of the magnetic body, located between the plurality of first windings and the plurality of second windings, and penetrating the magnetic body; the third side is connected between the first side and the second side.

[0017] In one embodiment, each of the isolation trenches includes a gap, and the plurality of magnetic fillers are filled in the gap.

[0018] In one embodiment, the cross-section of the gap is triangular.

[0019] In one embodiment, the magnetic element further includes a plurality of isolation rings surrounding the magnetic body, wherein the plurality of isolation rings engage with the two isolation grooves.

[0020] In one embodiment, one of the plurality of first windings and one of the plurality of second windings are located between two of the plurality of isolation rings.

[0021] In one embodiment, each of the isolation rings is partially embedded in the magnetic body and partially exposed outside the magnetic body.

[0022] In one embodiment, the plurality of isolation rings are made of an insulating material.

[0023] In one embodiment, the magnetic element further includes two ground electrodes disposed on opposite sides of the magnetic body, wherein the plurality of first windings and the plurality of second windings are located between the two ground electrodes.

[0024] In one embodiment, each of the first windings has fewer than one turn.

[0025] In one embodiment, each of the second windings has fewer than or equal to one turn.

[0026] In one embodiment, the first side is opposite to the second side.

[0027] In summary, magnetic filler is used to fill the space between the first winding and the second winding. Therefore, this invention can control leakage inductance and transient inductance by adjusting the permeability of the magnetic filler and / or adjusting the gap between the first winding and the second winding, thereby improving electromagnetic coupling and voltage stability in the circuit.

[0028] The advantages and spirit of the present invention can be further understood through the following detailed description of the invention and the accompanying drawings. Attached Figure Description

[0029] Figure 1 This is a perspective view of a magnetic element according to an embodiment of the present invention.

[0030] Figure 2 for Figure 1 A three-dimensional view of the magnetic components from another perspective.

[0031] Figure 3 for Figure 1 Exploded view of the magnetic components.

[0032] Figure 4 for Figure 1 A cross-sectional view of the magnetic components in the image.

[0033] Figure 5 for Figure 4 A partially enlarged view of the first winding and electrodes.

[0034] Figure 6 for Figure 4 A partial enlarged view of the first winding, the second winding, and the three electrodes.

[0035] Figure 7 This is a perspective view of a magnetic element according to another embodiment of the present invention.

[0036] Figure 8 for Figure 7 A three-dimensional view of the magnetic components from another perspective.

[0037] Figure 9 for Figure 7 Exploded view of the magnetic components.

[0038] Figure 10 This is a perspective view of a magnetic element according to another embodiment of the present invention.

[0039] Figure 11 for Figure 10 A cross-sectional view of the magnetic components in the image.

[0040] Figure 12 for Figure 10 A cross-sectional view of the magnetic components in the image.

[0041] List of reference numerals

[0042] 1, 1', 3: Magnetic elements

[0043] 10, 30: Magnetic bodies

[0044] 12, 32: First winding

[0045] 14, 34: Second winding

[0046] 16, 36: Magnetic filler

[0047] 18a, 18b, 42: Insulation layer

[0048] 20a, 20b, 20c, 20d, 44: Electrodes

[0049] 22: Isolation Ditch

[0050] 24: Isolation ring

[0051] 26: Grounding electrode

[0052] 38: Isolation strip

[0053] 40: Polymer adhesives

[0054] 100: First side

[0055] 102: Second side

[0056] 104: Third side

[0057] 106: Triangular area

[0058] 120: First end

[0059] 122: Second End

[0060] 124, 144: Corner

[0061] 140: Third end

[0062] 142: Fourth End

[0063] 220: Gap

[0064] X, Y: Profile lines Detailed Implementation

[0065] Please see Figures 1 to 6 , Figure 1 This is a perspective view of a magnetic element 1 according to an embodiment of the present invention. Figure 2 for Figure 1A three-dimensional view of magnetic element 1 from another perspective. Figure 3 for Figure 1 Exploded view of magnetic element 1 in the diagram. Figure 4 for Figure 1 A cross-sectional view of magnetic element 1 in the diagram. Figure 5 for Figure 4 A partially enlarged view of the first winding 12 and electrode 20b. Figure 6 for Figure 4 A partial enlarged view of the first winding 12, the second winding 14, and the three electrodes 20a, 20c, and 20d.

[0066] The magnetic element 1 of this invention can be an inductor or other magnetic element. For example... Figures 1 to 4 As shown, the magnetic element 1 includes a magnetic body 10, a first winding 12, a second winding 14, and a magnetic filler 16. The first winding 12 is disposed in the magnetic body 10, wherein a first end 120 and a second end 122 of the first winding 12 extend toward a first side 100 and a second side 102 of the magnetic body 10, respectively. In this embodiment, the first side 100 may be opposite to the second side 102, that is, the first end 120 and the second end 122 of the first winding 12 extend toward different sides of the magnetic body 10. The second winding 14 is disposed in the magnetic body 10, wherein a third end 140 and a fourth end 142 of the second winding 14 extend toward the first side 100 of the magnetic body 10, that is, the third end 140 and the fourth end 142 of the second winding 14 extend toward the same side of the magnetic body 10. Therefore, the first end 120 of the first winding 12 and the third end 140 and fourth end 142 of the second winding 14 are located on the first side 100 of the magnetic body 10, while the second end 122 of the first winding 12 is located on the second side 102 of the magnetic body 10. When the first winding 12 and the second winding 14 are encapsulated in the magnetic body 10, the first winding 12 partially covers the second winding 14, such as... Figure 4 As shown. In this embodiment, the second winding 14 is located on a portion of the first side 100 and the third side 104 of the magnetic body 10 that is not covered by the first winding 12, wherein the third side 104 is connected between the first side 100 and the second side 102.

[0067] The magnetic body 10 can be integrally formed from a magnetic material, and the first winding 12 and the second winding 14 can be made of copper. In practical applications, the first winding 12 can be a primary winding of the magnetic element 1, and the second winding 14 can be a secondary winding of the magnetic element 1.

[0068] In this embodiment, the number of turns in the first winding 12 may be less than 1 turn, and the number of turns in the second winding 14 may be less than or equal to 1 turn. It should be noted that the shapes of the first winding 12 and the second winding 14 can be determined according to the actual application and are not limited to the embodiment shown in the figure.

[0069] In this embodiment, the first winding 12 and the second winding 14 can be bent to form multiple bends 124 and 144. For example... Figure 4 As shown, the first winding 12 can be bent to form a three-corner 124, and the second winding 14 can be bent to form a four-corner 144, but is not limited thereto. The first end 120 of the first winding 12 extends from one corner 124 of the first winding 12, such that after the first winding 12 is encapsulated in the magnetic body 10, the magnetic body 10 forms a triangular region 106 adjacent to the first winding 12. The triangular region 106 is used to enhance the magnetic properties of the magnetic element 1.

[0070] In this embodiment, the cross-section of the first winding 12 may be larger than the cross-section of the second winding 14. Furthermore, as... Figure 5 and Figure 6 As shown, the first winding 12 and the second winding 14 can be covered by insulating layers 18a and 18b, wherein the first end 120, the second end 122, the third end 140, and the fourth end 142 are exposed from the insulating layers 18a and 18b. Furthermore, the first end 120, the second end 122, the third end 140, and the fourth end 142 exposed from the insulating layers 18a and 18b form electrodes 20a, 20b, 20c, and 20d. For example, the first end 120 can extend obliquely to form electrode 20a, the second end 122 can extend vertically to form electrode 20b, the third end 140 can extend horizontally to form electrode 20c, and the fourth end 142 can extend vertically to form electrode 20d, wherein electrode 20c is located between electrode 20a and electrode 20d, and electrode 20b is opposite to electrodes 20a, 20c, and 20d. Since the third end 140 extends horizontally to form electrode 20c and the fourth end 142 extends vertically to form electrode 20d, the distance between electrodes 20c and 20d can be increased to reduce the risk of short circuit. Electrodes 20a, 20b, 20c, and 20d can be electroplated electrodes, mainly composed of copper, nickel, and tin from top to bottom, but are not limited to this. The materials of insulating layers 18a and 18b can be polymer adhesives, oxides, ceramic powders, etc., depending on the actual application. It should be noted that the first winding 12 and the second winding 14 can be partially exposed in the bottom insulating layers 18a and 18b to form electrodes 20a, 20c, and 20d at the exposed first winding 12 and second winding 14, or the first winding 12 and the second winding 14 can be exposed on the entire bottom insulating layers 18a and 18b to form electrodes 20a, 20c, and 20d at the exposed first winding 12 and second winding 14.

[0071] Magnetic filler 16 is filled between the first winding 12 and the second winding 14. In this embodiment, the material of magnetic filler 16 may be amorphous powder, nanocrystalline powder, carbonyl iron powder, alloy powder, high magnetic flux powder, iron-silicon-aluminum (sendust), molybdenum permalloy powder (MPP), or ferrite. The composition may be carbon, silicon, chromium, iron, boron, cobalt, niobium, or nickel. The composition may be a mixture of magnetic material and polymer adhesive (or glass beads, or ceramic powder, or oxide), or a magnetic strip.

[0072] In this embodiment, two isolation trenches 22 may be formed on the first side 100 and the third side 104 of the magnetic body 10, wherein the two isolation trenches 22 are located between the first winding 12 and the second winding 14 and penetrate through opposite sides of the magnetic body 10. Each isolation trench 22 includes a gap 220 located between the first winding 12 and the second winding 14, wherein the cross-section of the gap 220 may be triangular. Magnetic filler 16 is also filled in the gap 220. The isolation trenches 22 are below the surface of the magnetic body 10 and below the electrodes. In addition, the isolation trenches 22 may exist between the first winding 12 and the second winding 14, typically between the two electrodes. The configuration of the isolation trenches 22 can improve the withstand voltage between the first winding 12 and the second winding 14.

[0073] Since the magnetic filler 16 is filled between the first winding 12 and the second winding 14, the leakage inductance and transient inductance of the magnetic element 1 can be controlled by adjusting the permeability of the magnetic filler 16 and / or adjusting the gap 220 between the first winding 12 and the second winding 14, thereby improving the electromagnetic coupling and voltage stability in the circuit.

[0074] Please see Figures 7 to 9 , Figure 7 This is a perspective view of magnetic element 1' according to another embodiment of the present invention. Figure 8 for Figure 7 A three-dimensional view of the magnetic element 1' from another perspective. Figure 9 for Figure 7 Exploded view of magnetic element 1' in the diagram.

[0075] like Figures 7 to 9As shown, the magnetic element 1' includes a magnetic body 10, a plurality of first windings 12, a plurality of second windings 14, a plurality of magnetic fillers 16, and a plurality of isolation rings 24. The plurality of first windings 12 are disposed within the magnetic body 10 and arranged at intervals, and the plurality of second windings 14 are also disposed within the magnetic body 10 and arranged at intervals, with each of the first windings 12 partially covering the plurality of second windings 14. Furthermore, the plurality of magnetic fillers 16 fill the spaces between the plurality of first windings 12 and the plurality of second windings 14. In this embodiment, one of the plurality of first windings 12 and one of the plurality of second windings 14 can form a primary winding and a secondary winding of the magnetic element 1'. Therefore, compared to the magnetic element 1 described above, the magnetic element 1' of the present invention can be an array inductor or other array magnetic elements.

[0076] As described above, a first end 120 and a second end 122 of each first winding 12 extend toward a first side 100 and a second side 102 of the magnetic body 10, respectively. Similarly, a third end 140 and a fourth end 142 of each second winding 14 extend toward the first side 100 of the magnetic body 10. It should be noted that the components with the same labels as those shown in Figures 7-9 and Figures 1-6 operate on roughly the same principle, and will not be described again here.

[0077] In this embodiment, two isolation trenches 22 are still formed on the first side 100 and the third side 104 of the magnetic body 10, wherein the two isolation trenches 22 are located between the plurality of first windings 12 and the plurality of second windings 14, and penetrate through the opposite sides of the magnetic body 10. Each isolation trench 22 includes a gap 220 located between the first winding 12 and the second winding 14, wherein the cross-section of the gap 220 may be triangular. Magnetic filler 16 is also filled in the gap 220.

[0078] Since the magnetic filler 16 is filled between the first winding 12 and the second winding 14, the leakage inductance and transient inductance of the magnetic element 1' can be controlled by adjusting the permeability of the magnetic filler 16 and / or adjusting the gap 220 between the first winding 12 and the second winding 14, thereby improving the electromagnetic coupling and voltage stability in the circuit.

[0079] like Figure 7 and Figure 8As shown, when the isolation ring 24 is encapsulated in the magnetic body 10, the isolation ring 24 surrounds the magnetic body 10 and engages with the two isolation grooves 22. In this embodiment, each isolation ring 24 may be partially embedded in the magnetic body 10 and partially exposed outside the magnetic body 10. The isolation grooves 22 and isolation rings 24 may exist between the first winding 12 and the second winding 14, typically between two electrodes. The configuration of the isolation rings 24 and the isolation grooves 22 can improve the withstand voltage between the first winding 12 and the second winding 14. Furthermore, the isolation rings 24 are used to block all paths of surface short circuits, thereby improving the withstand voltage of the magnetic element 1'. In addition, one of the plurality of first windings 12 and one of the plurality of second windings 14 are located between two of the plurality of isolation rings 24, so that the magnetic lines of force of the first windings 12 and the second windings 14 are not blocked by the isolation rings 24. In this embodiment, the isolation rings 24 may be made of polymers, ceramics, or other materials with high resistivity.

[0080] In this embodiment, the magnetic element 1' may include two ground electrodes 26 disposed on opposite sides of the magnetic body 10, wherein the first winding 12 and the second winding 14 are located between the two ground electrodes 26.

[0081] Please see Figures 10 to 12 , Figure 10 This is a perspective view of the magnetic element 3 according to another embodiment of the present invention. Figure 11 for Figure 10 Cross-sectional view of magnetic element 3 along line XX. Figure 12 for Figure 10 Cross-sectional view of magnetic element 3 along the YY line.

[0082] like Figures 10 to 12 As shown, the magnetic element 3 includes a magnetic body 30, a plurality of first windings 32, a plurality of second windings 34, a plurality of magnetic fillers 36, and a spacer bar 38. The plurality of first windings 32 are disposed within the magnetic body 30 and arranged at intervals, and the plurality of second windings 34 are also disposed within the magnetic body 30 and arranged at intervals, with each of the first windings 32 partially covering the plurality of second windings 34. Furthermore, a plurality of magnetic fillers 36 fill the spaces between the plurality of first windings 32 and the plurality of second windings 34. In this embodiment, one of the plurality of first windings 32 and one of the plurality of second windings 34 can form a primary winding and a secondary winding of the magnetic element 3. Therefore, the magnetic element 3 of the present invention can be an array inductor or other array magnetic elements.

[0083] After bonding, assembling, and baking the first winding 32 and the second winding 34 (e.g., primary winding and secondary winding), a polymer adhesive 40 (e.g., a thermosetting polymer adhesive) can be filled into the root (triangular region) between the first winding 32 and the second winding 34. Furthermore, an insulating layer 42 can be used to completely cover the outer circumference of the first winding 32 and the second winding 34 (e.g., copper wire) to block internal short-circuit paths, and a surface insulating strip 38 can be used to block surface short-circuit paths between any two electrodes 44 of the first winding 32 and the second winding 34, thereby improving the withstand voltage between the electrodes 44. In this embodiment, the insulating strip 38 can be made of epoxy molding compounds (EMC) and is integrally molded with the magnetic body 30 to become part of the magnetic element 3.

[0084] In summary, magnetic filler is used to fill the space between the first winding and the second winding. Therefore, this invention can control leakage inductance and transient inductance by adjusting the permeability of the magnetic filler and / or adjusting the gap between the first winding and the second winding, thereby improving electromagnetic coupling and voltage stability in the circuit.

[0085] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made in accordance with the claims of the present invention should be included within the scope of the present invention.

Claims

1. A magnetic element comprising: A magnetic body; A first winding is disposed in the magnetic body, and a first end and a second end of the first winding extend toward a first side and a second side of the magnetic body, respectively. A second winding is disposed in the magnetic body, a third end and a fourth end of the second winding extending toward the first side of the magnetic body, and the first winding partially covers the second winding; and A magnetic filler is used to fill the space between the first winding and the second winding.

2. The magnetic element as claimed in claim 1, wherein the first winding has fewer than one turn.

3. The magnetic element as claimed in claim 1, wherein the second winding has fewer than or equal to one turn.

4. The magnetic element as claimed in claim 1, wherein the first side is opposite to the second side.

5. The magnetic element as claimed in claim 1, wherein two isolation trenches are formed on the first side and a third side of the magnetic body, located between the first winding and the second winding, and penetrating the magnetic body; the third side is connected between the first side and the second side.

6. The magnetic element of claim 5, wherein each of the isolation trenches includes a gap, and the magnetic filler is filled in the gap.

7. The magnetic element of claim 6, wherein the cross-section of the gap is triangular.

8. The magnetic element of claim 1, wherein the first end extends from a corner of the first winding, such that the magnetic body forms a triangular region adjacent to the first winding.

9. The magnetic element as claimed in claim 1, wherein the third end extends horizontally to form an electrode, and the fourth end extends vertically to form another electrode.

10. The magnetic element of claim 1, wherein the first winding and the second winding are covered by an insulating layer; electrodes are formed on the first end, the second end, the third end and the fourth end exposed outside the insulating layer.

11. The magnetic element of claim 1, wherein the cross-section of the first winding is larger than the cross-section of the second winding.

12. A magnetic element comprising: A magnetic body; Multiple first windings are disposed in the magnetic body and arranged at intervals, with a first end and a second end of each first winding extending toward a first side and a second side of the magnetic body, respectively. A plurality of second windings are disposed in the magnetic body and arranged at intervals, with a third end and a fourth end of each second winding extending toward the first side of the magnetic body, and the plurality of first windings partially covering the plurality of second windings; and Multiple magnetic fillers are filled between the multiple first windings and the multiple second windings.

13. The magnetic element of claim 12, wherein two isolation trenches are formed on the first side and a third side of the magnetic body, located between the plurality of first windings and the plurality of second windings, and penetrating the magnetic body; the third side is connected between the first side and the second side.

14. The magnetic element of claim 13, wherein each of the isolation trenches includes a gap, and the plurality of magnetic fillers fill the gap.

15. The magnetic element of claim 14, wherein the cross-section of the gap is triangular.

16. The magnetic element of claim 13, further comprising a plurality of isolation rings surrounding the magnetic body, wherein the plurality of isolation rings engage with the two isolation grooves.

17. The magnetic element of claim 16, wherein one of the plurality of first windings and one of the plurality of second windings are located between two of the plurality of isolation rings.

18. The magnetic element of claim 16, wherein each of the isolation rings is partially embedded in the magnetic body and partially exposed outside the magnetic body.

19. The magnetic element of claim 16, wherein the plurality of isolation rings are made of an insulating material.

20. The magnetic element of claim 12, further comprising two grounding electrodes disposed on opposite sides of the magnetic body, wherein the plurality of first windings and the plurality of second windings are located between the two grounding electrodes.

21. The magnetic element of claim 12, wherein each of the first windings has fewer than one turn.

22. The magnetic element of claim 12, wherein each of the second windings has fewer than or equal to one turn.

23. The magnetic element of claim 12, wherein the first side is opposite to the second side.

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