inductive component

Abstract

This invention provides an inductor assembly comprising a first magnetic core, a second magnetic core, an inner magnetic core, and a flat winding portion. The first and second magnetic cores are connected to each other in opposite directions to form a closed space. The first magnetic core includes a first cover and a first side portion, and the second magnetic core includes a second cover and a second side portion. The first and second side portions are connected to each other, and the first and second cover portions are spaced apart from each other. The inner magnetic core is disposed between the first and second magnetic cores and housed within the closed space. The inner magnetic core includes a body portion and two protrusions connected to two opposite ends of the body portion. The flat winding portion is housed within the closed space and wound around the inner magnetic core. The two protrusions of the inner magnetic core form a first gap and a second gap with the first and second cover portions, respectively.

Description

Technical Field

[0001] This case relates to an inductor component, and more particularly to an inductor component that reduces AC losses. Background Technology

[0002] Converters such as boost power factor correction (PFC), semi-bridgeless PFC, totem-pole PFC, and LLC resonant converters need to operate at high switching frequencies. Therefore, high-frequency inductors are widely used because they can reduce the size of magnetic components.

[0003] When an inductor operates at high frequencies, power losses can be divided into DC losses caused by direct current and AC losses caused by alternating current. At high frequencies, AC losses caused by the eddy current effect and proximity effect result in uneven current distribution during conduction. Typically, AC losses have a greater impact than DC losses.

[0004] Traditionally, Litz wire is used instead of solid copper wire as the winding to reduce AC losses. However, due to limitations in inductor type and size, this method is only suitable for conventional inductors and not for thin inductors or their related applications.

[0005] Therefore, developing an inductor component that can improve upon the shortcomings of the aforementioned conventional technologies is an urgent need at present. Summary of the Invention

[0006] The purpose of this invention is to provide an inductor assembly in which the windings and inner core of the inductor assembly are disposed within a closed space formed by the core, so that the magnetic flux generated by the windings is not exposed. Therefore, AC losses caused by adjacent components are reduced, and electromagnetic interference (EMI) is prevented. Furthermore, since the type of winding in this invention is not limited, the applicability of the inductor assembly is improved.

[0007] According to one aspect of the concept, this invention provides an inductor assembly comprising a first magnetic core, a second magnetic core, an inner magnetic core, and a flat winding portion. The first and second magnetic cores are connected to each other in opposite directions to form a closed space. The first magnetic core includes a first cover and a first side portion, and the second magnetic core includes a second cover and a second side portion. The first and second side portions are connected to each other, and the first and second cover portions are spaced apart from each other. The inner magnetic core is disposed between the first and second magnetic cores and is housed within the closed space. The inner magnetic core includes a body portion and two protrusions, which are respectively connected to two opposite ends of the body portion. The flat winding portion is housed within the closed space and wound around the body portion of the inner magnetic core. The two protrusions of the inner magnetic core form a first gap and a second gap with the first cover and the second cover, respectively, wherein the first gap and the second gap extend in a direction parallel to a winding plane of the flat winding portion.

[0008] In some embodiments, the enclosed space includes a main chamber and two recessed chambers. The main chamber is formed by a first side portion and a second side portion. The two recessed chambers are formed in the first cover portion and the second cover portion, respectively. The body portion of the inner magnetic core is disposed in the main chamber, and the two protruding portions of the inner magnetic core are disposed in the two recessed chambers, respectively.

[0009] In some embodiments, the two recessed chambers correspond at least in size or shape to the two protrusions of the inner magnetic core.

[0010] In some embodiments, the second radius of both recessed chambers is smaller than the first radius of the main chamber.

[0011] In some embodiments, the first cover includes a first concave surface and a first concave wall, the first concave surface and the second concave wall together forming one of two concave chambers, and the second cover includes a second concave surface and a second concave wall, the second concave surface and the second concave wall together forming the other of two concave chambers.

[0012] In some embodiments, the two protruding portions of the inner magnetic core form a third gap and a fourth gap with the first cover and the second cover, respectively, wherein the third gap and the fourth gap extend in a direction perpendicular to the winding plane of the flat winding portion.

[0013] In some embodiments, the first gap, the second gap, the third gap, and the fourth gap form a continuous channel space.

[0014] In some embodiments, the first and second gaps or the third and fourth gaps are filled with insulating material.

[0015] In some embodiments, the first cover includes a first concave surface and a first concave wall, the second cover includes a second concave surface and a second concave wall, each protrusion includes an outer surface and an outer wall, wherein a first gap is formed between the first concave surface and the outer surface of one of the two protrusions, and a second gap is formed between the second concave surface and the outer surface of the other of the two protrusions.

[0016] In some embodiments, a third gap is formed between the outer wall of the first concave wall and the outer wall of one of the two protrusions, and a fourth gap is formed between the outer wall of the second concave wall and the outer wall of the other of the two protrusions.

[0017] In some embodiments, the first cover portion further includes a first edge surface adjacent to the first concave wall and the first side portion, the second cover portion further includes a second edge surface adjacent to the second concave wall and the second side portion, and each protrusion further includes an inner surface adjacent to the outer wall and the body portion, wherein the first edge surface is aligned with the inner surface of one of the two protrusions, and the second edge surface is aligned with the inner surface of the other of the two protrusions.

[0018] In some embodiments, the inner core comprises two sub-inner cores, which correspond to the first core and the second core, respectively.

[0019] In some embodiments, each sub-core includes one of two protrusions and a sub-body portion, with the two sub-body portions of the two sub-cores forming a body portion.

[0020] In some embodiments, the two sub-body portions are aligned with each other and separated by an air gap.

[0021] In some embodiments, the two sub-body parts are connected to each other.

[0022] In some embodiments, the first magnetic core, the second magnetic core, and the two sub-cores are assembled using virtual plane alignment.

[0023] In some embodiments, the inner magnetic core is integrally formed.

[0024] In some embodiments, the inner magnetic core is an I-type magnetic core, and the flat winding portion is a PCB winding coil.

[0025] In some embodiments, the first side has at least one first hole, the second side has at least one second hole, and the first hole of the first magnetic core and the second hole of the second magnetic core form an opening.

[0026] In some embodiments, the opening is used to accommodate the inlet and outlet ends of the flat winding portion. Attached Figure Description

[0027] Figure 1 This is a three-dimensional structural diagram of the inductor component according to a preferred embodiment of the present invention.

[0028] Figure 2 for Figure 1 A cross-sectional structural diagram of the inductor component 1.

[0029] Figure 3 for Figure 1 A cross-sectional structural diagram of the first and second magnetic cores.

[0030] Figure 4 for Figure 1 An exploded view of the inductor component 1.

[0031] Figure 5 for Figure 1 An exploded view of the inductor component 1, wherein, Figure 5 and Figure 4 Their perspectives are different.

[0032] Figure 6 This is a three-dimensional structural diagram of the inductor component 1a according to another preferred embodiment of the present invention.

[0033] Figure 7 for Figure 6 A cross-sectional structural diagram of the inductor component 1a.

[0034] Figure 8 for Figure 6 An exploded view of the inductor component 1a.

[0035] Figure 9 This is a three-dimensional structural diagram of the inductor component 1b according to another preferred embodiment of the present invention.

[0036] Figure 10 for Figure 9 An exploded view of the inductor component 1b.

[0037] Figure 11 This is a three-dimensional structural diagram of the inductor component 1c according to another preferred embodiment of the present invention.

[0038] Figure 12 for Figure 11 An exploded view of the inductor component 1c.

[0039] List of reference numerals

[0040] 1, 1a, 1b, 1c: Inductor components

[0041] 10a: Main chamber

[0042] 10b: Recessed chamber

[0043] 2: First magnetic core

[0044] 20: First cover

[0045] 21: First side

[0046] 201: First concave surface

[0047] 202: First concave wall

[0048] 203: First edge surface

[0049] 3: Second magnetic core

[0050] 30: Second cover

[0051] 31: Second side

[0052] 301: Second concave surface

[0053] 302: Second concave wall

[0054] 303: Second edge surface

[0055] 4, 4a: Inner magnetic core

[0056] 40: Body part

[0057] 41: Protrusion

[0058] 411: Outer surface

[0059] 412: outer wall

[0060] 413: Inner surface

[0061] 42: Inner core

[0062] 420: Sub-body part

[0063] 43: Inner core

[0064] 430: Sub-body part

[0065] 5: Flat winding section

[0066] 50: Input terminal

[0067] 51: Outgoing cable end

[0068] H1: First hole

[0069] H2: Second hole

[0070] O: Opening

[0071] g1: First gap

[0072] g2: Second gap

[0073] g3: Third gap

[0074] g4: Fourth gap

[0075] g5: Air gap

[0076] W1: First radius

[0077] W2: Second radius Detailed Implementation

[0078] Some typical embodiments that embody 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 forms, all of which do not depart from the scope of this invention, and the descriptions and illustrations therein are for illustrative purposes only, and are not intended to limit this invention.

[0079] Figure 1 This is a three-dimensional structural diagram of the inductor component 1 according to a preferred embodiment of this invention. Figure 2 for Figure 1 A cross-sectional structural diagram of the inductor component 1. Figure 4 for Figure 1 An exploded view of the inductor component 1. Figure 5 for Figure 1 An exploded view of the inductor component 1, wherein, Figure 5 and Figure 4 The perspectives are different. Please refer to [link / reference]. Figure 1 , Figure 2 , Figure 4 and Figure 5 The inductor assembly 1 of this invention includes a first magnetic core 2, a second magnetic core 3, an inner magnetic core 4, and a flat winding portion 5. The first magnetic core 2 and the second magnetic core 3 are connected to each other in opposite directions to form a closed space. The first magnetic core 2 includes a first cover portion 20 and a first side portion 21, with the first side portion 21 extending from the first cover portion 20. The second magnetic core 3 includes a second cover portion 30 and a second side portion 31, with the second side portion 31 extending from the second cover portion 30. The first side portion 21 and the second side portion 31 are connected to each other, and the first cover portion 20 and the second cover portion 30 are spaced apart from each other.

[0080] An inner magnetic core 4 is disposed between the first magnetic core 2 and the second magnetic core 3, and is housed within an enclosed space. The inner magnetic core 4 includes a body portion 40 and two protrusions 41, wherein the two protrusions 41 are respectively connected to two opposite ends of the body portion 40. In some embodiments, the inner magnetic core 4 is an I-type magnetic core, and the body portion 40 and the two protrusions 41 are cylinders, with the radius of the body portion 40 being smaller than the radius of the two protrusions 41.

[0081] The flat winding portion 5 is housed within an enclosed space and is wound around the body portion 40 of the inner magnetic core 4. The winding plane is defined as the plane in which the winding direction of the flat winding portion 5 is located.

[0082] There are multiple gaps between the inner magnetic core 4 and the first magnetic core 2 and the second magnetic core 3, the positions of which are shown in the figure. Figure 2 In the middle. Please see. Figure 2 The two protrusions 41 of the inner magnetic core 4 form a first gap g1 and a second gap g2 with the first cover portion 20 of the first magnetic core 2 and the second cover portion 30 of the second magnetic core 3, respectively, wherein the first gap g1 and the second gap g2 extend in a direction parallel to the winding plane of the flat winding portion 5. Specifically, one of the protrusions 41 of the inner magnetic core 4 forms a first gap g1 with the first cover portion 20 of the first magnetic core 2, and the first gap g1 extends in a direction parallel to the winding plane of the flat winding portion 5. The other protrusion 41 of the inner magnetic core 4 forms a second gap g2 with the second cover portion 30 of the second magnetic core 3, and the second gap g2 extends in a direction parallel to the winding plane of the flat winding portion 5. In this case, the types of the inner magnetic core 4 and the flat winding portion 5 are not limited. In some embodiments, the inner magnetic core 4 is a type I magnetic core, and the flat winding portion 5 may be, for example, but not limited to, a PCB winding coil, a solid flat wire coil, or a foil wire coil. In some embodiments, the enclosed space defined by the first magnetic core 2 and the second magnetic core 3 is used to prevent the magnetic flux generated by the flat winding portion 5 from being exposed.

[0083] In this case, by placing the windings and inner magnetic core 4 of the inductor assembly 1 within the enclosed space formed by the first magnetic core 2 and the second magnetic core 3, the magnetic flux generated by the windings is not exposed. Therefore, AC losses caused by adjacent components are reduced, and electromagnetic interference is prevented. Furthermore, since the type of winding in this case is not limited, the applicability of the inductor assembly 1 can be improved.

[0084] The following details the enclosed space as defined above in this case. Please refer to Figures 2 and 3 as well. Figure 3 for Figure 1 A cross-sectional structural diagram of the first magnetic core 2 and the second magnetic core 3 is shown. The enclosed space includes a main chamber 10a and two recessed chambers 10b. The main chamber 10a is formed by a first side portion 21 and a second side portion 31, and the two recessed chambers 10b are formed by a first cover portion 20 and a second cover portion 30, respectively. The body portion 40 of the inner magnetic core 4 is disposed within the main chamber 10a, and the two protrusions 41 of the inner magnetic core 4 are respectively disposed within the two recessed chambers 10b. In some embodiments, the two recessed chambers 10b correspond to the two protrusions 41 of the inner magnetic core 4 at least in size or shape. In some embodiments, the two protrusions 41 are cylindrical in shape, and the two recessed chambers 10b are cylindrical spaces, respectively corresponding to the cylinders of the protrusions 41. In other embodiments, the shapes of the protrusions 41 and the recessed chambers 10b are not limited to cylinders and cylindrical spaces, as long as the shapes of the protrusions 41 correspond to the corresponding recessed chambers 10b. In some embodiments, the second radius W2 of the recessed chamber 10b is smaller than the first radius W1 of the main chamber 10a.

[0085] Please see Figure 2 , Figure 3 , Figure 4 and Figure 5 The first cover portion 20 includes a first concave surface 201 and a first concave wall 202 surrounding the first concave surface 201. The first concave surface 201 and the first concave wall 202 together form one of the two concave chambers 10b. The second cover portion 30 includes a second concave surface 301 and a second concave wall 302 surrounding the second concave surface 301. The second concave surface 301 and the second concave wall 302 together form the other of the two concave chambers 10b.

[0086] In addition to the first gap g1 and the second gap g2, there are other gaps between the inner magnetic core 4 and the first magnetic core 2 and the second magnetic core 3. Please refer again. Figure 2 Two protrusions 41 of the inner magnetic core 4 form a third gap g3 and a fourth gap g4 with the first cover portion 20 and the second cover portion 30, respectively, wherein the third gap g3 and the fourth gap g4 extend in a direction perpendicular to the winding plane of the flat winding portion 5. Therefore, the first gap g1 and the second gap g2 are perpendicular to the third gap g3 and the fourth gap g4. Specifically, one of the protrusions 41 of the inner magnetic core 4 forms a third gap g3 with the first cover portion 20 of the first magnetic core 2, wherein the third gap g3 extends in a direction perpendicular to the winding plane of the flat winding portion 5. The other protrusion 41 of the inner magnetic core 4 forms a fourth gap g4 with the second cover portion 30 of the second magnetic core 3, wherein the fourth gap g4 extends in a direction perpendicular to the winding plane of the flat winding portion 5. In some embodiments, the third gap g3 and the fourth gap g4 communicate in an enclosed space. The third gap g3 communicates with the first gap g1, and the fourth gap g4 communicates with the second gap g2.

[0087] In some embodiments, the first gap g1, the second gap g2, the third gap g3, and the fourth gap g4 form a continuous channel space. In some embodiments, the first gap g1 and the second gap g2, or the third gap g3 and the fourth gap g4, are filled with an insulating material. The insulating material is used to prevent the inner magnetic core 4 from directly contacting the first magnetic core 2 and / or the second magnetic core 3. In embodiments where both the second gap g2 and the fourth gap g4 are filled with insulating material, the insulating material located between the inner magnetic core 4 and the second magnetic core 3 ensures that the inner magnetic core 4 does not directly contact the second magnetic core 3. In other embodiments, the first gap g1, the second gap g2, the third gap g3, and the fourth gap g4 are all filled with insulating material. In this case, the insulating material may be selected from materials such as epoxy resin, silicone, bakelite, ceramics, or insulating sheets such as Nomex®.

[0088] The gaps described above will be defined in detail below based on the structural details. Please refer to [link / reference]. Figure 2 , Figure 4 and Figure 5Each protrusion 41 of the inner magnetic core 4 includes an outer surface 411 and an outer wall 412 surrounding the outer surface 411. A first gap g1 is formed between the first concave surface 201 and the outer surface 411 of one of the two protrusions 41, and a second gap g2 is formed between the second concave surface 301 and the outer surface 411 of the other of the two protrusions 41.

[0089] As for the third gap g3 and the fourth gap g4, the third gap g3 is formed between the first concave wall 202 and the outer wall 412 of one of the two protrusions 41, and the fourth gap g4 is formed between the second concave wall 302 and the outer wall 412 of the other of the two protrusions 41.

[0090] The first cover portion 20 further includes a first edge surface 203 adjacent to the first recessed wall 202 and the first side portion 21, and the second cover portion 30 further includes a second edge surface 303 adjacent to the second recessed wall 302 and the second side portion 31. Each protrusion 41 further includes an inner surface 413 adjacent to the outer wall 412 and the body portion 40, the first edge surface 203 being aligned with the inner surface 413 of one of the two protrusions 41, and the second edge surface 303 being aligned with the inner surface 413 of the other of the two protrusions 41.

[0091] Please refer to the following: Figure 1 , Figure 4 and Figure 5 The first side portion 21 has at least one first hole H1, and the second side portion 31 has at least one second hole H2, wherein the first hole H1 of the first magnetic core 2 and the second hole H2 of the second magnetic core 3 form an opening O. Figure 1 , Figure 4 , Figure 5 and Figure 6 In the illustrated embodiment, two first holes H1 are provided on opposite sides of the first side 21, and two second holes H2 are provided on opposite sides of the second side 31, with the two first holes H1 corresponding to the two second holes H2. The first hole H1 of the first magnetic core 2 and the second hole H2 of the second magnetic core 3 form two openings O located on opposite sides. In the above embodiment, one of the two openings O is used to accommodate the input end 50 and the output end 51 of the flat winding portion 5. In other embodiments, this invention may have only one first hole H1 and one second hole H2, forming a single opening O, which is used to accommodate the input end 50 and the output end 51 on one side of the inductor assembly 1. In other embodiments, one side of the inductor assembly 1 is formed by one first hole H1 and one second hole H2 to accommodate the first opening (not shown), while the other side of the inductor assembly 1 is formed by another first hole H1 and another second hole H2 to accommodate the second opening (not shown).

[0092] At Figure 1 and Figure 2The inner magnetic core 4 of the inductor assembly 1 shown in the embodiment is integrally formed; however, the structure of the inner magnetic core in this embodiment is not limited. Specifically, the inner magnetic core in this embodiment can be integrally formed or can be composed of two components. Please refer to... Figure 6 , Figure 7 and Figure 8 ,At Figure 6 , Figure 7 and Figure 8 In the illustrated embodiment, the inner magnetic core 4a of the inductor assembly 1a is composed of two components. This case... Figure 6 , Figure 7 and Figure 8 The inductor assembly 1a shown is denoted by the same reference numerals as elements with similar structures and functions in inductor assembly 1, and will not be described again here. In this embodiment, the inner magnetic core 4a includes two sub-inner magnetic cores 42 and 43, which correspond to the first magnetic core 2 and the second magnetic core 3, respectively. The sub-inner magnetic cores 42 and 43 include one of two protrusions 41 and sub-body portions 420 and 430, and the two sub-body portions 420 and 430 of the two sub-inner magnetic cores 42 and 43 form a body portion 40. Specifically, the sub-inner magnetic core 42 includes one of two protrusions 41 and a sub-body portion 420, and the sub-inner magnetic core 43 includes the other of two protrusions 41 and a sub-body portion 430. The two sub-body portions 420 and 430 are aligned and separated by an air gap g5. In some embodiments, the spacing of the air gap g5 is much smaller than the spacing of the first gap g1, the second gap g2, the third gap g3, and the fourth gap g4. In some embodiments, the spacing of the air gap g5 is so small as to be negligible. In some embodiments, the first magnetic core 2, the second magnetic core 3, and the two sub-cores 42 and 43 are assembled using virtual plane alignment. It should be particularly noted that... Figure 1 and Figure 2 In the embodiment shown, two sub-body portions 420 and 430 are interconnected to form a body portion 40.

[0093] In the above embodiments, there are two first holes H1 and two second holes H2, so there are two corresponding openings O. However, in practice, there is no limitation on the number of first holes H1, second holes H2, and openings O in this embodiment. Furthermore, the structure of the inner magnetic core is also not limited. The following example illustrates an embodiment with four first holes H1, second holes H2, and openings O, where the inner magnetic core is integrally formed. Please refer to... Figure 9 and Figure 10 In this embodiment, four first holes H1 are respectively provided on the four sides of the first side portion 21, and four second holes H2 are respectively provided on the four sides of the second side portion 31. Figure 9 and Figure 10The inductor assembly 1b shown is denoted by the same reference numerals as elements with similar structures and functions in inductor assemblies 1 and 1a, and will not be described again here. In this embodiment, the four first holes H1 of the first magnetic core 2 and the four second holes H2 of the second magnetic core 3 form four openings O, one of which is used to accommodate the inlet end 50 and outlet end 51 of the flat winding section 5. In this embodiment, the integrally formed inner magnetic core 4 and Figure 1 and Figure 2 The integrally formed inner magnetic core 4 shown is the same, so it will not be described again here.

[0094] The following example illustrates an embodiment with four holes (H1, H2, and O) and an inner magnetic core consisting of two components. Please refer to [link / reference]. Figure 11 and Figure 12 In this embodiment, four first holes H1 are respectively provided on the four sides of the first side portion 21, and four second holes H2 are respectively provided on the four sides of the second side portion 31. Figure 11 and Figure 12 The inductor assembly 1c shown is denoted by the same reference numerals as elements with similar structures and functions in inductor assemblies 1, 1a, and 1b, and will not be described again here. In this embodiment, the four first holes H1 of the first magnetic core 2 and the four second holes H2 of the second magnetic core 3 form four openings O, one of which is used to accommodate the input end 50 and the output end 51 of the flat winding section 5. In this embodiment, the inner magnetic core 4a is composed of two components, and the inner magnetic core 4a composed of the two components and... Figure 6 and Figure 7 The inner magnetic core 4a of the illustrated embodiment is the same, and therefore will not be described again here. In some embodiments, the input terminal 50 and the output terminal 51 may extend from different openings O. In some embodiments, the opening O may be used to accommodate other terminals, such as heat dissipation terminals for heat dissipation, or air ducts for cooling purposes.

[0095] In some embodiments, the inductor components 1, 1a, 1b, and 1c described above are suitable for thin inductors or related applications. In some embodiments, the inductor components 1, 1a, 1b, and 1c described above are suitable for converters such as boost power factor correction (PFC), semi-bridgeless PFC, totem-pole PFC, and LLC resonant converters.

[0096] In summary, the inductor assembly of this invention, by placing its windings and inner magnetic core within a closed space formed by the magnetic core, prevents the magnetic flux generated by the windings from being exposed. Therefore, AC losses caused by adjacent components are reduced, and electromagnetic interference is prevented. Furthermore, since the type of winding in this invention is not limited, the applicability of the inductor assembly is improved.

[0097] It should be noted that the above are merely preferred embodiments for illustrating this case, and this case is not limited to the described embodiments. The scope of this case is determined by the appended claims. Furthermore, this case can be modified in various ways by those skilled in the art, but all modifications shall not depart from the protection sought by the appended claims.

Claims

1. An inductor assembly, comprising: A first magnetic core and a second magnetic core are joined together in opposite directions to form a closed space, wherein... The first magnetic core includes a first cover portion and a first side portion, and the second magnetic core includes a second cover portion and a second side portion. The first side portion and the second side portion are connected to each other, and the first cover portion and the second cover portion are spaced apart from each other. An inner magnetic core is disposed between the first magnetic core and the second magnetic core and housed within the enclosed space. The inner magnetic core includes a body portion and two protrusions, wherein the two protrusions are respectively connected to two opposite ends of the body portion; and A flat winding portion is housed within the enclosed space and wound around the body portion of the inner magnetic core. The two protruding portions of the inner magnetic core form a first gap and a second gap with the first cover and the second cover, respectively, wherein the first gap and the second gap extend in a direction parallel to a winding plane of the flat winding portion.

2. The inductor assembly as claimed in claim 1, wherein, The enclosed space includes a main chamber and two recessed chambers. The main chamber is formed by the first side portion and the second side portion. The two recessed chambers are formed by the first cover portion and the second cover portion, respectively. The body portion of the inner magnetic core is disposed in the main chamber, and the two protruding portions of the inner magnetic core are disposed in the two recessed chambers, respectively.

3. The inductor assembly as described in claim 2, wherein, The two recessed cavities correspond, at least in size or shape, to the two protrusions of the inner magnetic core.

4. The inductor assembly as claimed in claim 3, wherein, The second radius of each of the two concave chambers is smaller than the first radius of the main chamber.

5. The inductor assembly as claimed in claim 2, wherein, The first cover includes a first concave surface and a first concave wall, the first concave surface and the first concave wall together forming one of the two concave chambers. The second cover includes a second concave surface and a second concave wall, the second concave surface and the second concave wall together forming the other of the two concave chambers.

6. The inductor assembly as claimed in claim 1, wherein, The two protruding portions of the inner magnetic core form a third gap and a fourth gap with the first cover and the second cover, respectively, wherein the third gap and the fourth gap extend in a direction perpendicular to the winding plane of the flat winding portion.

7. The inductor assembly as claimed in claim 6, wherein, The first gap, the second gap, the third gap, and the fourth gap form a continuous channel space.

8. The inductor assembly as claimed in claim 6, wherein, An insulating material is filled in the first gap and the second gap or the third gap and the fourth gap.

9. The inductor assembly as claimed in claim 6, wherein, The first cover includes a first concave surface and a first concave wall, the second cover includes a second concave surface and a second concave wall, each of the protrusions includes an outer surface and an outer wall, wherein the first gap is formed between the first concave surface and the outer surface of one of the two protrusions, and the second gap is formed between the second concave surface and the outer surface of the other of the two protrusions.

10. The inductor assembly of claim 9, wherein, The third gap is formed between the first concave wall and the outer wall of one of the two protrusions, and the fourth gap is formed between the second concave wall and the outer wall of the other of the two protrusions.

11. The inductor assembly of claim 9, wherein, The first cover portion further includes a first edge surface adjacent to the first concave wall and the first side portion, the second cover portion further includes a second edge surface adjacent to the second concave wall and the second side portion, and each of the protrusions further includes an inner surface adjacent to the outer wall and the body portion, wherein the first edge surface is aligned with the inner surface of one of the two protrusions, and the second edge surface is aligned with the inner surface of the other of the two protrusions.

12. The inductor assembly of claim 11, wherein, The inner core comprises two sub-inner cores, which correspond to the first core and the second core, respectively.

13. The inductor assembly of claim 12, wherein, Each of the inner cores includes one of the two protrusions and a body portion, and the two body portions of the two inner cores form the body portion.

14. The inductor assembly of claim 13, wherein, The two sub-body sections are aligned with each other and separated by an air gap.

15. The inductor assembly of claim 13, wherein, The two sub-body parts are connected to each other.

16. The inductor assembly of claim 12, wherein, The first magnetic core, the second magnetic core, and the two sub-cores are assembled using a virtual plane alignment.

17. The inductor assembly of claim 1, wherein, The inner magnetic core is formed in one piece.

18. The inductor assembly of claim 1, wherein, The inner magnetic core is a type I magnetic core, and the flat winding section is a PCB winding coil.

19. The inductor assembly of claim 1, wherein, The first side has at least one first hole, the second side has at least one second hole, and the first hole of the first magnetic core and the second hole of the second magnetic core form an opening.

20. The inductor assembly of claim 19, wherein, The opening is used to accommodate an input terminal and an output terminal of the flat winding section.

Images