Magnetic element

Abstract

A magnetic element includes a first magnetic core element, a second magnetic core element, and at least one coil. The first magnetic core element includes a first molded support that covers a first portion of a magnetic core assembly by an injection molding process. The second magnetic core element includes a second molded support that covers a second portion of the magnetic core assembly by the injection molding process. The first magnetic core element and the second magnetic core element are assembled to form a first column and a second column. The first column and the second column each include a plurality of magnetic cores stacked in a direction toward an outside or an inside of the magnetic element. The at least one coil is wound on at least one of the first column and the second column.

Description

Technical Field

[0001] This invention relates to a magnetic element, and more particularly to a magnetic element that uses an injection molding process to form a molded support for covering a magnetic core assembly. Background Technology

[0002] Magnetic components are important electronic parts used for energy storage, energy conversion, and electrical isolation. They are present in most circuits. Generally, magnetic components mainly include reactors, transformers, and inductors. In known magnetic components, the support, core, and spacers are assembled using adhesive. However, too many components can make the assembly process overly complex. The cumulative tolerances of individual components can lead to excessively large overall tolerances after assembly, making it difficult to control screw fastening positions, resulting in poor electrical characteristics, misaligned appearance, inability to miniaturize, increased amount of potting compound, and increased processing time, ultimately leading to wasted cost or space. Summary of the Invention

[0003] The purpose of this invention is to provide a magnetic element that utilizes an injection molding process to form a molded support that covers a magnetic core assembly, thereby solving the aforementioned problems.

[0004] According to one embodiment, the magnetic element of the present invention includes a first magnetic core element, a second magnetic core element, and at least one coil. The first magnetic core element includes a first molding bracket that covers a first portion of a magnetic core assembly via an injection molding process. The second magnetic core element includes a second molding bracket that covers a second portion of the magnetic core assembly via an injection molding process. The first and second magnetic core elements are assembled to form a first pillar and a second pillar. The first and second pillars each include a plurality of magnetic cores stacked together in a direction toward the outside of the magnetic element. A joint of the first pillar has a first gap, and a joint of the second pillar has a second gap, wherein the first gap is larger than the second gap. At least one coil is wound around at least one of the first and second pillars.

[0005] According to another embodiment, the magnetic element of the present invention includes a first magnetic core element, a second magnetic core element, and at least one coil. The first magnetic core element includes a first molding bracket that covers a first portion of a magnetic core assembly via an injection molding process. The second magnetic core element includes a second molding bracket that covers a second portion of the magnetic core assembly via an injection molding process. The first and second magnetic core elements are assembled to form a first pillar and a second pillar. The first and second pillars each include a plurality of magnetic cores stacked together toward the inside of the magnetic element. The length of the first pillar is greater than the length of the second pillar. At least one coil is wound around at least one of the first and second pillars.

[0006] In summary, this invention utilizes injection molding to form a first and second molded support for the magnetic core assembly, and then assembles the first and second magnetic core elements to form a first and a second column. In one embodiment, the magnetic cores can be stacked together towards the outer side of the magnetic element to form a first and a second gap at the junction of the first and second columns, wherein the first gap is larger than the second gap. The first and second gaps can be used to absorb the tolerances of the magnetic cores and / or spacers, thereby reducing the length difference between the first and second columns. Thus, the lengths of the first and second columns will be approximately the same after assembly. Furthermore, since the dimensional tolerances of the magnetic core assembly and / or spacer assembly are smaller after assembly, the thickness of the molded support can be thinner, reducing the height or width of the magnetic element. In another embodiment, the magnetic cores can be stacked together towards the inner side of the magnetic element, so that the length of the first column is greater than the length of the second column, thereby reducing the gap tolerance between the first and second columns, and / or reducing the tolerance of the magnetic path. In this embodiment, the thickness of the molded bracket can be relatively thick to maintain the shape of the magnetic element, so that the magnetic element is not affected by the shape tolerance of the assembled magnetic core assembly and / or spacer assembly.

[0007] The advantages and spirit of the present invention can be further understood from the following detailed description of the invention and the accompanying drawings. Attached Figure Description

[0008] Figure 1 This is a perspective view of a magnetic element according to an embodiment of the present invention.

[0009] Figure 2 for Figure 1 A diagram showing the combination of the first and second magnetic core elements.

[0010] Figure 3 for Figure 2 Exploded view of the first and second magnetic core components.

[0011] Figure 4 for Figure 3 Front view of the magnetic core assembly.

[0012] Figure 5 for Figure 4 The diagram shows the assembly of the magnetic core group.

[0013] Figure 6 for Figure 5 Side view of the magnetic core assembly.

[0014] Figure 7 This is a cross-sectional view of a magnetic element according to another embodiment of the present invention.

[0015] Figure 8This is a front view of a magnetic element according to another embodiment of the present invention.

[0016] Figure 9 for Figure 8 The front view of the magnetic element after the coil has been removed.

[0017] Figure 10 A 3D view of a temperature sensor mounted on a bracket.

[0018] Figure 11 This is an exploded view of the temperature sensor bracket and heat-conducting components.

[0019] Figure 12 This is a diagram showing the combination of a first magnetic core element and a second magnetic core element according to another embodiment of the present invention.

[0020] Figure 13 for Figure 12 A front view of the core assembly of the first and second magnetic core elements.

[0021] Figure 14 for Figure 13 The diagram shows the assembly of the magnetic core group.

[0022] The attached figures are labeled as follows: 1: Magnetic components 10: First magnetic core element 12: Second magnetic core element 14: Coil 16: Base 18: First fixed element 20: Second fixing element 22: First column 24: Second column 26: Magnetic core assembly 26a: Part 1 26b: Part Two 28: Top pin 30: Spacer 32: First Spacing Structure 34: Second Spacing Structure 36: Opening 38: Filling space 40: Temperature sensor 42: Bracket 44: Groove 46: Thermal conductive components 100: First molding bracket 102, 122: Fixing holes 120: Second molding support 220, 240: Joint 260: Magnetic core 262: Winding section 264: Non-winding section D1: Outer direction D2: Inner direction G1: First gap G2: Second gap L1, L2: Length W1: First width W2: Second width W3: Third width W4: Fourth Width Detailed Implementation

[0023] 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 1 A diagram showing the combination of the first magnetic core element 10 and the second magnetic core element 12. Figure 3 for Figure 2 Exploded view of the first magnetic core element 10 and the second magnetic core element 12 in the image. Figure 4 for Figure 3 Front view of magnetic core assembly 26 in the middle. Figure 5 for Figure 4 The assembly diagram of magnetic core assembly 26 in the middle. Figure 6 for Figure 5 Side view of the magnetic core assembly 26.

[0024] The magnetic element 1 of this invention can be a reactor, transformer, inductor, or other magnetic element. For example... Figures 1 to 3 As shown, the magnetic element 1 includes a first magnetic core element 10, a second magnetic core element 12, at least one coil 14, a base 16, a first fixing element 18, and a second fixing element 20. The first magnetic core element 10 and the second magnetic core element 12 are assembled to form a first column 22 and a second column 24. The first fixing element 18 is used to fix the first magnetic core element 10 to the base 16, and the second fixing element 20 is used to fix the second magnetic core element 12 to the base 16. The first fixing element 18 and the second fixing element 20 can be screws or bolts, but are not limited thereto. In this embodiment, the joint between the first magnetic core element 10 and the second magnetic core element 12 can be opposite each other and not fixed, so that the space between the first magnetic core element 10 and the second magnetic core element 12 can be used to absorb the expansion volume of the first magnetic core element 10 and the second magnetic core element 12 due to temperature changes. The coil 14 is wound around at least one of the first column 22 and the second column 24. In this embodiment, two coils 14 are wound around the first column 22 and the second column 24 respectively.

[0025] like Figure 3As shown, the first magnetic core element 10 includes a first molding bracket 100 and a first portion 26a of a magnetic core assembly 26, and the second magnetic core element 12 includes a second molding bracket 120 and a second portion 26b of the magnetic core assembly 26. In this embodiment, the magnetic core assembly 26 includes a plurality of magnetic cores 260, wherein the plurality of magnetic cores 260 can be divided into the first portion 26a of the first magnetic core element 10 and the second portion 26b of the second magnetic core element 12.

[0026] like Figure 1 and Figure 2 As shown, the first fixing element 18 can fix the first magnetic core element 10 to the base 16 through the fixing hole 102 of the first molding bracket 100, and the second fixing element 20 can fix the second magnetic core element 12 to the base 16 through the fixing hole 122 of the second molding bracket 120. In this embodiment, the fixing holes 102 and 122 can be circular holes or regular polygonal holes, so that after the first fixing element 18 and the second fixing element 20 pass through the fixing holes 102 and 122 and are fixed to the base 16, the first molding bracket 100 and the second molding bracket 120 remain fixed.

[0027] This invention utilizes an injection molding process to form a first molding bracket 100 covering the first portion 26a of the magnetic core assembly 26 and a second molding bracket 120 covering the second portion 26b of the magnetic core assembly 26. For example... Figure 4 As shown, the present invention places the first portion 26a of the magnetic core assembly 26 into a mold (not shown in the figure). In this mold, the ejector pin 28 abuts against the magnetic core 260, causing the magnetic cores 260 to stack on top of each other in the outward direction D1 of the magnetic element 1. Next, the present invention performs an injection molding process to form a first molding support 100 covering the first portion 26a of the magnetic core assembly 26. Similarly, as... Figure 4 As shown, the present invention allows the second portion 26b of the magnetic core assembly 26 to be placed into another mold (not shown in the figure). In this mold, the ejector pin 28 abuts against the magnetic core 260, causing the magnetic cores 260 to stack together in the outward direction D1 of the magnetic element 1. Next, the present invention performs an injection molding process to form a second molding support 120 covering the second portion 26b of the magnetic core assembly 26. Thus, after the first magnetic core element 10 and the second magnetic core element 12 are assembled, the first pillar 22 and the second pillar 24 each contain a plurality of magnetic cores 260 stacked together in the outward direction D1 of the magnetic element 1.

[0028] Since the first pillar 22 and the second pillar 24 are formed by stacking multiple smaller magnetic cores 260, the present invention can reduce the molding cost of manufacturing the magnetic cores 260 and increase the service life of the molding mold, thereby reducing the molding cost of the magnetic cores 260 and increasing the molding yield. However, each magnetic core 260 or spacer has individual tolerances. After the first magnetic core element 10 and the second magnetic core element 12 are assembled, the individual tolerances of multiple magnetic cores and / or spacers will accumulate, causing the lengths of the first pillar 22 and the second pillar 24 to be different. To solve the above problem, the present invention stacks the magnetic cores 260 together in the outward direction D1 of the magnetic element 1 to form a first gap G1 at a joint 220 of the first pillar 22 and a second gap G2 at a joint 240 of the second pillar 24, as shown. Figure 5 As shown. Therefore, after the first magnetic core element 10 and the second magnetic core element 12 are assembled, the joint 220 of the first column 22 has a first gap G1, and the joint 240 of the second column 24 has a second gap G2, wherein the first gap G1 is larger than the second gap G2 due to the different tolerances of the magnetic core 240 and / or the spacer. The first gap G1 and the second gap G2 can be used to absorb the tolerances of the magnetic core 260 and / or the spacer, so as to reduce the length difference between the first column 22 and the second column 24. Thus, the lengths of the first column 22 and the second column 24 will be approximately the same after assembly. In addition, since the dimensional tolerance of the magnetic core assembly 26 is smaller after assembly, the thickness of the first molding bracket 100 and the second molding bracket 120 can be thinner, so as to reduce the height or width of the magnetic element 1.

[0029] Since the first molding bracket 100 and the second molding bracket 120 can be tightly bonded to the magnetic core 260 without gaps through injection molding, the overall structural rigidity of the magnetic element 1 is relatively increased, while also reducing the risk of failure in reliability tests due to mechanical shock or vibration. In addition, the tolerances of each component are absorbed after the injection molding process, and the appearance dimensions of the magnetic element 1 are more stable and accurate. Furthermore, the gaps between the first magnetic core element 10, the second magnetic core element 12, and the base 16 are also relatively stable. Therefore, this invention can effectively control the amount of injection molding material. If the amount of injection molding material is controlled stably, the injection time can also be stabilized, thereby saving the time of re-injection.

[0030] It should be noted that in some embodiments, the two adjacent magnetic cores 260 at the joint 240 of the second column 24 can contact each other, so that the second gap G2 is zero.

[0031] In this embodiment, the magnetic element 1 may further include a first spacer structure 32 and a second spacer structure 34. For example... Figure 5As shown, the first spacer structure 32 is disposed in the first gap G1, and the second spacer structure 34 is disposed in the second gap G2. Since the first gap G1 is larger than the second gap G2, the thickness of the first spacer structure 32 is greater than the thickness of the second spacer structure 34. In this embodiment, the first spacer structure 32 and the second spacer structure 34 can be injection-molded materials formed by an injection molding process. In another embodiment, the first spacer structure 32 and the second spacer structure 34 can be spacers. If the first spacer structure 32 and the second spacer structure 34 are spacers, they can be first stacked with the magnetic core 260 in a mold, and then an injection molding process is performed to form the first molded support 100 and the second molded support 120.

[0032] In this embodiment, the shapes of the first magnetic core element 10 and the second magnetic core element 12 can be determined according to the number of magnetic cores 260. For example, the shapes of the first magnetic core element 10 and the second magnetic core element 12 can be U-shaped, J-shaped, L-shaped, I-shaped, or other shapes. Preferably, the shapes of the first magnetic core element 10 and the second magnetic core element 12 can be the same (e.g., U-shaped or J-shaped), so that the first magnetic core element 10 and the second magnetic core element 12 can share a single mold to save the cost of other molds. In this embodiment, the magnetic element 1 may also include a plurality of spacers 30, wherein each spacer 30 is disposed between two of the plurality of magnetic cores 260. The spacers 30 can be made of non-magnetic material or of magnetic material with a magnetic permeability lower than that of the magnetic core assembly 26. The magnetic cores 260 and the spacers 30 can be joined by adhesive bonding or by injection molding, depending on the actual application. In one embodiment, the first spacer structure 32 and the second spacer structure 34 may also be omitted from the joints 220 and 240.

[0033] like Figure 5 and Figure 6 As shown, the magnetic core assembly 26 has a wound portion 262 and a non-wound portion 264. In this embodiment, a first width W1 of the wound portion 262 is greater than a second width W2 of the non-wound portion 264, a third width W3 of the wound portion 262 is less than a fourth width W4 of the non-wound portion 264, and the product of the first width W1 and the third width W3 is equal to the product of the second width W2 and the fourth width W4 (that is, W1...). W3=W2 W4). In this embodiment, the fourth width W4 is greater than the third width W3. When the fourth width W4 increases, the second width W2 decreases, thereby reducing the overall height of the magnetic element 1.

[0034] Please see Figure 7 , Figure 7 This is a cross-sectional view of a magnetic element 1 according to another embodiment of the present invention.

[0035] like Figure 7 As shown, each joint 220 and 240 of the first column 22 and the second column has an opening 36. The positions of the openings 36 correspond to... Figure 4 The position of the ejector pin 28 is shown, and the opening 36 is formed during the injection molding process. After the injection molding process is completed, one of the plurality of magnetic cores 260 will be exposed from the opening 36. It should be noted that the present invention can provide more ejector pins in other positions in the mold, so that a portion of the plurality of magnetic cores 260 is exposed after the injection molding process, thereby improving heat dissipation efficiency. In addition, a filling space 38 may exist between the magnetic core 260 and a recessed structure of the spacer 30, so that the injection molding material fills the filling space 38 through the injection molding process. Thus, the magnetic core 260 and the spacer 30 can be connected by the injection molding process. It should be noted that the shape of the spacer 30 can be determined according to the actual application, therefore, the present invention is not limited to the embodiment shown in the figure. Furthermore, the first molding support 100 and the second molding support 120 further form the first spacer structure 32 and the second spacer structure 34 during the injection molding process. Since the first molding bracket 100 and the second molding bracket 120 can completely cover the magnetic core 260 with injection molding material (e.g., plastic), the creepage distance for safety regulations can be completely ignored.

[0036] Please see Figure 8 as well as Figure 9 , Figure 8 This is a front view of the magnetic element 1 according to another embodiment of the present invention. Figure 9 for Figure 8 The front view after removing coil 14 from magnetic element 1.

[0037] like Figure 8 and Figure 9As shown, the magnetic element 1 may further include a temperature sensor 40 and a bracket 42. The temperature sensor 40 is disposed on the bracket 42, and the bracket 42 is disposed between the coils 14, such that the temperature sensor 40 is disposed adjacent to one of the coils 14. Furthermore, at least one groove 44 is formed on at least one inner surface of the first molding support 100 and the second molding support 120, and the temperature sensor 40 is disposed at a position corresponding to the at least one groove 44. In this embodiment, two grooves 44 are respectively formed on the opposing inner surfaces of the first molding support 100 and the second molding support 120, but this is not a limitation. Preferably, the temperature sensor 40 interferes with the coils 14 to ensure that the temperature sensor 40 accurately measures the temperature of the magnetic element 1. The groove 44 is used to accommodate at least a portion of the coil 14. When the volume of all components increases due to heat or tolerance, at least a portion of the coil 14 can extend into the groove 44, such that the groove 44 absorbs the tolerance and thermal expansion of all components, thereby preventing damage to the temperature sensor 40. It should be noted that, in addition to the first forming bracket 100 and the second forming bracket 120, the groove 44 can also be applied to the assembled bracket.

[0038] Please see Figure 10 as well as Figure 11 , Figure 10 A perspective view of the temperature sensor 40 mounted on the bracket 42. Figure 11 This is an exploded view of the temperature sensor 40, bracket 42, and heat-conducting component 46.

[0039] like Figure 11 As shown, the magnetic element 1 may further include a heat-conducting element 46. The heat-conducting element 46 may be a ceramic sheet, but is not limited thereto. The heat-conducting element 46 is disposed on the bracket 42, and the temperature sensor 40 is disposed on the heat-conducting element 46, as shown. Figure 10 As shown. Thus, the temperature of the magnetic element 1 can be effectively conducted to the temperature sensor 40 via the heat-conducting element 46, thereby effectively measuring the maximum temperature of the magnetic element 1.

[0040] Please see Figures 12 to 14 , Figure 12 This is a diagram showing the combination of the first magnetic core element 10 and the second magnetic core element 12 according to another embodiment of the present invention. Figure 13 for Figure 12 A front view of the core assembly 26 consisting of the first magnetic core element 10 and the second magnetic core element 12. Figure 14 for Figure 13 The diagram shows the assembly of magnetic core group 26.

[0041] The present invention can replace the first magnetic core element 10 and the second magnetic core element 12 of the above-mentioned magnetic element 1 with... Figure 12 The first magnetic core element 10 and the second magnetic core element 12 are shown. Figure 12 and Figure 13As shown, the present invention utilizes an injection molding process to form a first molding bracket 100 covering the first portion 26a of the magnetic core assembly 26 and a second molding bracket 120 covering the second portion 26b of the magnetic core assembly 26. Figure 13 As shown, the present invention places the first portion 26a of the magnetic core assembly 26 into a mold (not shown in the figure). In this mold, the ejector pin 28 abuts against the magnetic core 260, causing the magnetic cores 260 to stack on top of each other in the inward direction D2 of the magnetic element 1. Next, the present invention performs an injection molding process to form a first molding support 100 covering the first portion 26a of the magnetic core assembly 26. Similarly, as... Figure 13 As shown, the present invention allows the second portion 26b of the magnetic core assembly 26 to be placed into another mold (not shown in the figure). In this mold, the ejector pin 28 abuts against the magnetic core 260, causing the magnetic cores 260 to stack together in the inward direction D2 of the magnetic element 1. Next, the present invention performs an injection molding process to form a second molding support 120 covering the second portion 26b of the magnetic core assembly 26. Thus, after the first magnetic core element 10 and the second magnetic core element 12 are assembled, the first pillar 22 and the second pillar 24 each contain a plurality of magnetic cores 260 stacked together in the inward direction D2 of the magnetic element 1, and the length L1 of the first pillar 22 is greater than the length L2 of the second pillar 24, as shown. Figure 14 As shown.

[0042] In this embodiment, the magnetic cores 260 are stacked together in the inward direction D2 of the magnetic element 1, so that the length L1 of the first column 22 is greater than the length L2 of the second column 24, thereby reducing the gap tolerance between the first column 22 and the second column 24, and / or reducing the tolerance of the magnetic path. In this embodiment, the thickness of the first forming bracket 100 and the second forming bracket 120 can be relatively thick to maintain the shape of the magnetic element 1, so that the magnetic element 1 is not affected by the shape tolerance of the assembled magnetic core assembly 26. After assembly, the tolerance of the magnetic path is small regardless of whether there is a gap between the first column 22 and the second column 24. In another embodiment, the first column 22 may have at least one first gap G1, and / or the second column 24 may have at least one second gap G2, wherein the sum of at least one first gap G1 is as large as the sum of at least one second gap G2. It should be noted that the components with the same labels as those shown in Figures 12-14 and Figures 1-11 have roughly the same working principle, and will not be described again here.

[0043] like Figure 14As shown, the first column 22 may have three first gaps G1, and the second column 24 may have three second gaps G2, wherein the three first gaps G1 are distributed in the first column 22, the three second gaps G2 are distributed in the second column 24, and the sum of the three first gaps G1 is the same as the sum of the three second gaps G2. In some embodiments, the first column 22 may have a single first gap G1, and the second column 24 may have a single second gap G2, and the single first gap G1 and the single second gap G2 are the same size. In some embodiments, spacers 30 may be provided in the first gap G1 and / or the second gap G2. In some embodiments, the first molding support 100 and the second molding support 120 may be doped with magnetic powder. In some embodiments, the first gaps G1 and the second gaps G2 may be omitted, so that the present invention can reduce the tolerance of the magnetic path caused by the tolerance of the magnetic core 260.

[0044] like Figure 12 and Figure 14 As shown, the first molding bracket 100 has an opening 36 away from the joints 220 and 240 of the first pillar 22 and the second pillar 24, and one of the plurality of magnetic cores 260 is exposed through the opening 36. Similar to the opening 36 of the first molding bracket 100, the second molding bracket 120 also has an opening (not shown in the figure) away from the joints 220 and 240 of the first pillar 22 and the second pillar 24, and one of the plurality of magnetic cores 260 is exposed through the opening. The position of the opening 36 corresponds to... Figure 13 The position of the ejector pin 28 is shown, and the opening 36 is formed during the injection molding process. After the injection molding process is completed, one of the plurality of magnetic cores 260 will be exposed from the opening 36. It should be noted that the present invention can provide more ejector pins in other positions in the mold, so that a portion of the plurality of magnetic cores 260 is exposed after the injection molding process, thereby improving heat dissipation efficiency.

[0045] In summary, this invention utilizes injection molding to form a first and second molded support for the magnetic core assembly, and then assembles the first and second magnetic core elements to form a first and a second column. In one embodiment, the magnetic cores can be stacked together towards the outer side of the magnetic element to form a first and a second gap at the junction of the first and second columns, wherein the first gap is larger than the second gap. The first and second gaps can be used to absorb the tolerances of the magnetic cores and / or spacers, thereby reducing the length difference between the first and second columns. Thus, the lengths of the first and second columns will be approximately the same after assembly. Furthermore, since the dimensional tolerances of the magnetic core assembly and / or spacer assembly are smaller after assembly, the thickness of the molded support can be thinner, reducing the height or width of the magnetic element. In another embodiment, the magnetic cores can be stacked together towards the inner side of the magnetic element, so that the length of the first column is greater than the length of the second column, thereby reducing the gap tolerance between the first and second columns, and / or reducing the tolerance of the magnetic path. In this embodiment, the thickness of the molded bracket can be relatively thick to maintain the shape of the magnetic element, so that the magnetic element is not affected by the shape tolerance of the assembled magnetic core assembly and / or spacer assembly.

[0046] 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 core assembly consists of multiple cores; A support frame, at least covering a portion of the magnetic core assembly, forms a first column and a second column; At least one coil is wound around at least one of the first column and the second column; At least one groove is formed on at least one inner surface between the first and second pillars of the bracket, and dynamically accommodates at least a portion of the at least one coil; and A temperature sensor is disposed at a position corresponding to the at least one groove and adjacent to the at least one coil.

2. The magnetic element as claimed in claim 1, comprising: A first magnetic core element, comprising: The first molded bracket of the bracket covers a first part of the magnetic core assembly by an injection molding process; A second magnetic core element, comprising: The bracket has a second molded bracket that covers a second part of the magnetic core assembly through the injection molding process. The first magnetic core element and the second magnetic core element are assembled to form the first column and the second column. The first column and the second column respectively contain a plurality of magnetic cores stacked on each other in the direction of the outer side of the magnetic element. A joint of the first column has a first gap, and a joint of the second column has a second gap. The first gap is larger than the second gap, and the length of the first column is equal to the length of the second column. A first thickness of a first outer structure is disposed at the joint of the first pillar of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; and A second thickness of a second outer structure is provided at the joint of the second column of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; in, The first outer structure has a first thickness greater than the second outer structure. The first outer structure and the second outer structure are part of the first molded bracket and / or the second molded bracket, and prevent the tolerances of the plurality of magnetic cores from affecting the shape of the first magnetic core element and the second magnetic core element.

3. The magnetic element as claimed in claim 2, wherein each of the joints between the first column and the second column has an opening, and one of the plurality of magnetic cores is exposed through the opening.

4. The magnetic element as claimed in claim 2, further comprising: A base; A first fixing element for fixing the first magnetic core element to the base; and A second fixing element is used to fix the second magnetic core element to the base; in, The joint between the first magnetic core element and the second magnetic core element is opposite to each other and is not fixed.

5. The magnetic element as claimed in claim 2, further comprising: A first spacer structure is disposed in the first gap; and A second spacer structure is disposed in the second gap, wherein the thickness of the first spacer structure is greater than the thickness of the second spacer structure.

6. The magnetic element as claimed in claim 5, wherein the first spacer structure and the second spacer structure are injection-molded materials formed by the injection molding process.

7. The magnetic element as claimed in claim 5, wherein the first spacer structure and the second spacer structure are spacers.

8. The magnetic element as claimed in claim 1, wherein the magnetic core assembly has a wound portion and a non-wound portion, a first width of the wound portion is greater than a second width of the non-wound portion, a third width of the wound portion is less than a fourth width of the non-wound portion, and the product of the first width and the third width is equal to the product of the second width and the fourth width.

9. The magnetic element of claim 1 further comprises a plurality of spacers, each spacer being disposed between two of the plurality of magnetic cores, the plurality of magnetic cores and the plurality of spacers being connected by a colloid or by an injection molding process.

10. The magnetic element of claim 9, wherein a filling space exists between the magnetic core and a recessed structure of the spacer, such that an injection molding material is filled into the filling space by an injection molding process.

11. The magnetic element of claim 1, further comprising: A bracket, located adjacent to the at least one coil; and A heat-conducting component is disposed on the bracket, and a temperature sensor is disposed on the heat-conducting component.

12. The magnetic element of claim 1, wherein the groove is recessed into the at least one inner surface between the first column and the second column in an opposite direction to the first column and the second column, an extension direction of the groove is the same as the winding direction of a single turn, and a portion of the at least one coil facing the groove is not fixed and dynamically extends in the winding direction of a single turn to be accommodated in the groove.

13. The magnetic element of claim 1, wherein the recess comprises at least two recesses, and the two recesses are respectively disposed on the two inner surfaces of the first column and the second column facing the temperature sensor.

14. The magnetic element of claim 1, comprising: A first magnetic core element, comprising: The first molded bracket of the bracket covers a first part of the magnetic core assembly by an injection molding process; A second magnetic core element, comprising: The bracket has a second molded bracket that covers a second part of the magnetic core assembly through the injection molding process. The first magnetic core element and the second magnetic core element are assembled to form the first column and the second column. The first column and the second column respectively contain a plurality of magnetic cores stacked on each other in the direction of the inner side of the magnetic element. The first column has at least one first gap, and the second column has at least one second gap. The sum of the at least one first gap and the sum of the at least one second gap are the same. The length of the first column is greater than the length of the second column. A first thickness of a first outer structure is disposed at a joint of the first pillar of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; and A second thickness of a second outer structure is provided at a joint of the second column of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; in, The first outer structure and the second outer structure are part of the structure of the first molded bracket and / or the second molded bracket, and prevent the tolerances of the plurality of magnetic cores from affecting the shape of the first magnetic core element and the second magnetic core element.

15. A magnetic element comprising: A core assembly consists of multiple cores; A support frame, at least covering a portion of the magnetic core assembly, forms a first column and a second column; At least one coil is wound around at least one of the first column and the second column; A bracket is disposed between the first column and the second column and adjacent to the at least one coil. The bracket has an opening, a receiving groove structure, and a connecting portion. The receiving groove structure is disposed in the opening, and the connecting portion extends from the inner wall of the opening to the receiving groove structure. A temperature sensor is disposed in the receiving groove structure of the bracket; and A heat-conducting element is disposed on the bracket and in contact with the temperature sensor.

16. The magnetic element of claim 15, wherein the thermally conductive element and the temperature sensor are stacked in the direction between the first column and the second column.

17. The magnetic element of claim 15, wherein the heat-conducting element is a ceramic sheet.

18. The magnetic element of claim 15, wherein the connecting portion further includes a second groove in the thickness direction, such that the thickness of at least a portion of the connecting portion is less than the thickness of the receiving groove structure and / or the thickness of the opening.

19. The magnetic element of claim 15 further includes at least one first groove formed on at least one inner surface between the first column and the second column of the support, and dynamically accommodating at least a portion of the at least one coil.

20. The magnetic element of claim 19, wherein the at least one first groove is recessed into the at least one inner surface between the first column and the second column in an opposite direction to the first column and the second column, an extension direction of the groove is the same as the winding direction of a single turn, and a portion of the at least one coil facing the groove is not fixed and dynamically extends in the winding direction of a single turn to be accommodated in the groove.

21. The magnetic element of claim 19, wherein the recess comprises at least two recesses, and the two recesses are respectively disposed on the two inner surfaces of the first column and the second column facing the temperature sensor.

22. The magnetic element of claim 15, comprising: A first magnetic core element, comprising: The first molded bracket of the bracket covers a first part of the magnetic core assembly by an injection molding process; A second magnetic core element, comprising: The bracket has a second molded bracket that covers a second part of the magnetic core assembly through the injection molding process. The first magnetic core element and the second magnetic core element are assembled to form the first column and the second column. The first column and the second column respectively contain a plurality of magnetic cores stacked on each other in the direction of the outer side of the magnetic element. A joint of the first column has a first gap, and a joint of the second column has a second gap. The first gap is larger than the second gap, and the length of the first column is equal to the length of the second column. A first thickness of a first outer structure is disposed at the joint of the first pillar of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; and A second thickness of a second outer structure is provided at the joint of the second column of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; in, The first outer structure has a first thickness greater than the second outer structure. The first outer structure and the second outer structure are part of the first molded bracket and / or the second molded bracket, and prevent the tolerances of the plurality of magnetic cores from affecting the shape of the first magnetic core element and the second magnetic core element.

23. The magnetic element of claim 22, wherein each of the joints between the first column and the second column has an opening, and one of the plurality of magnetic cores is exposed through the opening.

24. The magnetic element of claim 22, further comprising: A base; A first fixing element for fixing the first magnetic core element to the base; and A second fixing element is used to fix the second magnetic core element to the base; in, The joint between the first magnetic core element and the second magnetic core element is opposite to each other and is not fixed.

25. The magnetic element of claim 22, further comprising: A first spacer structure is disposed in the first gap; and A second spacer structure is disposed in the second gap, wherein the thickness of the first spacer structure is greater than the thickness of the second spacer structure.

26. The magnetic element of claim 25, wherein the first spacer structure and the second spacer structure are injection-molded materials formed by the injection molding process, wherein the magnetic core assembly has a wound portion and a non-wound portion, a first width of the wound portion is greater than a second width of the non-wound portion, a third width of the wound portion is less than a fourth width of the non-wound portion, and the product of the first width and the third width is equal to the product of the second width and the fourth width.

27. The magnetic element of claim 25, wherein the first spacer structure and the second spacer structure are spacers.

28. The magnetic element of claim 22 further comprises a plurality of spacers, each spacer being disposed between two of the plurality of magnetic cores, the plurality of magnetic cores and the plurality of spacers being connected by a colloid or by the injection molding process.

29. The magnetic element of claim 15, comprising: A first magnetic core element, comprising: The first molded bracket of the bracket covers a first part of the magnetic core assembly by an injection molding process; A second magnetic core element, comprising: The bracket has a second molded bracket that covers a second part of the magnetic core assembly through the injection molding process. The first magnetic core element and the second magnetic core element are assembled to form the first column and the second column. The first column and the second column respectively contain a plurality of magnetic cores stacked on each other in the direction of the inner side of the magnetic element. The first column has at least one first gap, and the second column has at least one second gap. The sum of the at least one first gap and the sum of the at least one second gap are the same. The length of the first column is greater than the length of the second column. A first thickness of a first outer structure is disposed at a joint of the first pillar of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; and A second thickness of a second outer structure is provided at a joint of the second column of the first magnetic core element or the second magnetic core element, located between the plurality of magnetic cores, for absorbing the tolerances of the plurality of magnetic cores; in, The first outer structure and the second outer structure are part of the structure of the first molded bracket and / or the second molded bracket, and prevent the tolerances of the plurality of magnetic cores from affecting the shape of the first magnetic core element and the second magnetic core element.

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