A magnetic element, inductor and transformer

Abstract

The disclosure provides a magnetic element, an inductor and a transformer, which comprises a magnetic core, a flat coil, the magnetic core comprises a winding column, and the flat coil is sleeved on the winding column; the flat coil is in an S-P-S structure; the flat coil comprises a bottom secondary layer, a bottom shielding layer, a primary main coil, a top shielding layer and a top secondary layer, and the primary main coil is located between the top shielding layer and the bottom shielding layer, and the primary main coil, the top shielding layer and the bottom shielding layer are located between the top secondary layer and the bottom secondary layer; the bottom shielding layer and the top shielding layer comprise shielding coils; the bottom secondary layer and the top secondary layer comprise secondary coils; the primary coil in the flat coil comprises the primary main coil and the shielding coil. By multiplexing the primary coil as the shielding coil, the primary coil can play the role of the main winding and the shielding effect, thereby improving the use efficiency and saving the layout space.

Description

Technical Field

[0001] This disclosure relates to the field of circuit components technology, and more particularly to a magnetic element, an inductor, and a transformer. Background Technology

[0002] In modern power systems and electronic devices, magnetic components play a crucial role, and optimizing the winding stack layout of their coils is essential for improving overall performance.

[0003] However, some magnetic components in related technologies have unreasonable winding stacking designs, resulting in wasted layout space for the winding stacking and affecting the efficiency and performance of the magnetic components.

[0004] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Utility Model Content

[0005] This disclosure provides a magnetic element, inductor, and transformer that at least partially overcomes the problem that the efficiency and performance of magnetic elements are affected by unreasonable coil winding stacking layout in related technologies.

[0006] Other features and advantages of this disclosure will become apparent from the following detailed description, or may be learned in part from practice of this disclosure.

[0007] According to a first aspect of this disclosure, a magnetic element is provided, comprising: a magnetic core, a flat coil, the magnetic core including a winding post, and the flat coil being sleeved on the winding post;

[0008] The flat coil has an SPS structure;

[0009] The flat coil includes: a bottom layer, a bottom shielding layer, a primary main coil, a top shielding layer, and a top layer, wherein the primary main coil is located between the top shielding layer and the bottom shielding layer, and the primary main coil, the top shielding layer, and the bottom shielding layer are all located between the top layer and the bottom layer.

[0010] The bottom shielding layer and the top shielding layer include: a shielding coil; the bottom secondary layer and the top secondary layer include: a secondary coil;

[0011] The primary coil in the flat coil includes a primary main coil and a shielding coil.

[0012] In one possible embodiment, the magnetic core further includes a first side post and a second side post disposed opposite to each other, the winding post being located between the first side post and the second side post, the edges of the first side post and the second side post being parallel to each other along a first direction; the length of the winding post is greater than its width, and the length direction of the winding post is the same as the first direction.

[0013] In one possible embodiment, the bottom shielding layer and / or the top shielding layer further include: a primary auxiliary winding.

[0014] In one possible embodiment, the bottom level and / or top level further include: a secondary auxiliary winding.

[0015] In one possible embodiment, one end of the shielding coil of the top shielding layer is connected to a static point, and the other end is connected to one end of the shielding coil of the bottom shielding layer.

[0016] The other end of the shielding coil of the bottom shielding layer is connected to one end of the primary main coil, and the other end of the primary main coil is connected to the primary moving point.

[0017] In one possible embodiment, the thickness of the primary and secondary side insulation layers is set to 0.1-0.3 mm.

[0018] In one possible embodiment, the turns ratio of the primary coil to the secondary coil is 7:1.

[0019] In one possible embodiment, the copper thickness of the primary coil is 3 oz or 4 oz; the copper thickness of the secondary coil is 2 oz.

[0020] In one possible embodiment, the number of PCB layers of the magnetic element may include any one of 6, 8, 10, and 12.

[0021] According to another aspect of this disclosure, an inductor is provided, including the magnetic element of the first aspect.

[0022] According to another aspect of this disclosure, a transformer is provided, including the magnetic element of the first aspect.

[0023] The embodiments of this disclosure provide a magnetic element, inductor, and transformer. The magnetic element includes a magnetic core and a flat coil. The magnetic core includes winding posts, and the flat coil is sleeved on the winding posts. The flat coil has an SPS structure. The flat coil includes a bottom layer, a bottom shielding layer, a primary main coil, a top shielding layer, and a top layer, with the primary main coil located between the top and bottom shielding layers. The primary main coil, top shielding layer, and bottom shielding layer are all located between the top and bottom layers. The bottom and top shielding layers include shielding coils. The bottom and top layers include secondary coils. The primary coil in the flat coil includes a primary main coil and a shielding coil. By reusing the primary coil as a shielding coil, it can serve as both a main winding and a shielding function, improving efficiency and saving layout space.

[0024] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0025] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0026] Obviously, the accompanying drawings described below are merely some embodiments of this disclosure. Those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0027] Figure 1 This diagram illustrates one of the winding stacks of a flat coil according to an embodiment of the present disclosure;

[0028] Figure 2 This is a second schematic diagram showing a winding stack of a flat coil according to an embodiment of the present disclosure;

[0029] Figure 3 This is the third schematic diagram showing a winding stack of a flat coil according to an embodiment of the present disclosure;

[0030] Figure 4 This is the fourth schematic diagram showing a winding stack of a flat coil according to an embodiment of the present disclosure;

[0031] Figure 5 Fifth schematic diagram showing a winding stack of a flat coil according to an embodiment of the present disclosure;

[0032] Figure 6 This diagram shows a circuit structure schematic of a winding according to an embodiment of the present disclosure;

[0033] Figure 7 A schematic diagram of the structure of a magnetic element in an embodiment of this disclosure is shown. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this disclosure, and not all of them. The components of the embodiments of this disclosure described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this disclosure provided in the accompanying drawings is not intended to limit the scope of the claimed disclosure, but merely represents selected embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without inventive effort are within the scope of protection of this disclosure.

[0035] In modern power systems and electronic devices, magnetic components play a crucial role, and optimizing the winding stack layout of their coils is essential for improving overall performance. An inappropriate layout design can affect multiple aspects, such as losses and efficiency, heat dissipation, and manufacturing processes.

[0036] However, some magnetic components in related technologies have unreasonable winding stacking designs, resulting in wasted layout space for the winding stacking and affecting the efficiency and performance of the magnetic components.

[0037] The deficiencies of the above solutions and the proposed solutions are the result of the inventor's practice and careful research. Therefore, the discovery process of the above problems and the solutions proposed in this disclosure below should be considered as the inventor's contribution to this disclosure.

[0038] The following detailed description of this exemplary implementation method is provided in conjunction with the accompanying drawings and embodiments.

[0039] This disclosure provides a magnetic element comprising: a magnetic core and a flat coil. The magnetic core includes a winding post, and the flat coil is sleeved on the winding post. The flat coil has an SPS (Surface Mount Power) structure.

[0040] A flat coil has a secondary-primary structure. A schematic diagram of the winding layers of a flat coil is shown below. Figure 1 As shown, it includes: bottom layer 1, bottom shielding layer 2, primary main coil 4, top shielding layer 5 and top layer 6, with the primary main coil 4 located between the top shielding layer 5 and the bottom shielding layer 2, and the primary main coil 4, the top shielding layer 2 and the bottom shielding layer 5 all located between the top layer 6 and the bottom layer 1.

[0041] The bottom shielding layer 2 and the top shielding layer 5 each include a shielding coil. The bottom secondary layer 1 and the top secondary layer 6 each include a secondary coil.

[0042] The primary coil 3 in the flat coil includes: the primary main coil 4 and the shielding coil.

[0043] In this embodiment of the disclosure, the winding stack is designed such that the two outermost layers are secondary windings and the inner layers are primary windings. The purpose is to reduce leakage inductance loss. Furthermore, the primary coil 3 of the flat coil is reused as a shielding coil. This not only serves as the main winding in the winding stack, but also shields common-mode noise and optimizes electromagnetic interference (EMI).

[0044] In one possible embodiment, since the thickness of the primary and secondary side insulation layers affects the leakage inductance, the thickness of the primary and secondary side insulation layers can be set to 0.1-0.3 mm to reduce leakage inductance.

[0045] The gaps between different layers of the primary coil can be set in a conventional manner, such as 0.05mm, 0.07mm, etc., and are not limited in this disclosure.

[0046] In one possible embodiment, the turns ratio of the primary coil and the secondary coil can be set to 7:1, that is, the ratio of the total turns of the shielding coil and the primary main coil 4 to the total turns of the secondary coil can be set to 7:1.

[0047] In one possible embodiment, in order to reduce winding losses on the inner primary side, the copper thickness of the primary coil can be set to 3 oz or 4 oz, and the copper thickness of the outer secondary coil can be set to 2 oz.

[0048] In one possible embodiment, the number of PCB layers for the magnetic element can include a variety of options, such as any one of 6, 8, 10, and 12.

[0049] Figure 2 A schematic diagram of a winding stack of a magnetic element according to an embodiment of this disclosure is shown, such as... Figure 2 As shown, the shielding coils in the bottom shielding layer 2 and the top shielding layer 5 are P1 and P2, respectively. The primary main coil includes P3-P14, and the total number of turns of the primary coil is 14. The secondary coils in the bottom layer 1 and the top layer 6 are S1 and S2, respectively. The total number of turns of the secondary coil is 2, and the ratio of the primary coil to the secondary coil is 7:1.

[0050] The copper thickness of the primary coil is set to 3 oz, the copper thickness of the shielding coil is set to 2 oz, and the copper thickness of the secondary coil is set to 2 oz.

[0051] in, Figure 2L1, L2, and L3 can be set as follows: the insulation layer thickness between the two primary main coils can be set to L1: 0.05mm; the insulation layer thickness between the primary main coil and the shielding coil can be set to L2: 0.07mm; and the insulation layer thickness between the primary and secondary sides can be set to L3: 0.15mm.

[0052] In one possible embodiment, since both the shielding layer and the primary main coil 4 belong to the primary coil 3, the connection method of the primary coil 3 includes: one end of the shielding coil of the top shielding layer 5 is connected to the stationary point, and the other end is connected to one end of the shielding coil of the bottom shielding layer 2; the other end of the shielding coil of the bottom shielding layer 2 is connected to one end of the primary main coil 4; and the other end of the primary main coil 4 is connected to the primary moving point.

[0053] like Figure 3 The connection method shown in the schematic diagram of the winding stack is as follows: one end of the shielding coil of the top shielding layer 5 (the first turn of the primary coil 3, P1) is connected to the stationary point, i.e., the positive electrode of the Bus capacitor; the other end of the shielding coil of the top shielding layer 5 is connected to one end of the shielding coil of the bottom shielding layer 2 (the second turn of the primary coil 3, P2); the other end of the shielding coil of the bottom shielding layer 2 is connected to the third turn of the primary coil 3, P3 is connected to P8 and P9 in sequence, P9 is connected to P14, and finally P14 is connected to the primary moving point.

[0054] It should be noted that the definitions of top layer and bottom layer in the embodiments of this disclosure are used to distinguish the two layers in the winding stack diagram. In actual use, they can be arbitrarily selected and applied. Top layer and bottom layer are equivalent.

[0055] For example, when connecting the shielding layer to the stationary point, it is not restricted whether the top shielding layer 5 or the bottom shielding layer 2 is connected to the stationary point. The connection method can also be: one end of the shielding coil of the bottom shielding layer 2 is connected to the stationary point, and the other end is connected to one end of the shielding coil of the top shielding layer 5; the other end of the shielding coil of the top shielding layer 5 is connected to one end of the primary main coil 4; and the other end of the primary main coil 4 is connected to the primary moving point.

[0056] In designs where the shielding layer is designed separately for the shielding coil, it's possible to add coils in opposite directions simultaneously, such as a portion clockwise and another portion counterclockwise. This design ensures that at least a portion of the coil's direction is opposite to the main winding direction or the secondary winding direction. However, this disclosure reuses a portion of the primary coil as the shielding coil, with all winding directions in the coil being the same. The solution in this disclosure optimizes the winding layout, saving space and improving efficiency and performance during use.

[0057] In one possible embodiment, the flat coil in this embodiment further includes a primary auxiliary winding, where the bottom shielding layer 2 and / or the top shielding layer 5 also include a primary auxiliary winding.

[0058] Primary auxiliary windings can be set in one or both layers of the shielding layer to power the primary-side integrated circuit (IC). Taking the setting of the primary auxiliary winding in the bottom shielding layer 2 as an example... Figure 4 This diagram illustrates a winding stack of a flat coil according to an embodiment of the present disclosure, such as... Figure 4 As shown, the bottom shielding layer 2 includes a primary auxiliary winding 21. The auxiliary winding wire diameter is made as small as possible to reduce the losses of the primary winding.

[0059] In one possible embodiment, the flat coil in this embodiment further includes a secondary auxiliary winding, where the bottom layer 1 and / or the top layer 6 also include a secondary auxiliary winding.

[0060] Secondary auxiliary windings can be set in one or both layers of the secondary layer to power the secondary IC. Taking the example of setting a primary auxiliary winding in the bottom shield layer 2 and a secondary auxiliary winding in the bottom secondary layer 1,... Figure 5 This diagram illustrates a winding stack of a flat coil according to an embodiment of the present disclosure, such as... Figure 5 As shown, the bottom shielding layer 2 includes a primary auxiliary winding 21, and the bottom secondary layer 1 includes a secondary auxiliary winding 11. The wire diameter of the auxiliary winding is as small as possible to reduce the loss of the primary winding.

[0061] In one possible embodiment, Figure 6 A schematic diagram of a circuit is shown to illustrate the design of the coil of the magnetic element in this disclosure, such as... Figure 6 As shown.

[0062] exist Figure 6 The circuit diagram mainly includes: a primary coil, a secondary coil, and auxiliary windings. Starting from the positive electrode B+ of the capacitor (Buscap), i.e., the stationary point, the winding passes through the first turn P1, the second turn P2, and the primary main coils P3-P14, finally reaching the primary moving point. The secondary coils are S1 and S2, and S3 and S4 are the secondary auxiliary windings. Additionally, Figure 6 The primary auxiliary winding (P_aux) is also marked in the circuit diagram.

[0063] In one possible embodiment, the magnetic core further includes a first side post and a second side post disposed opposite to each other, with a winding post located between the first side post and the second side post, and the edges of the first side post and the second side post being parallel to each other along a first direction; the length of the winding post is greater than its width, and the length direction of the winding post is the same as the first direction.

[0064] like Figure 7As shown, a schematic diagram of the first side post, the second side post, and the winding post is shown, as well as a schematic diagram of the first direction, which can be any of the directions indicated by the arrow.

[0065] The winding post can be a "racetrack-shaped" winding post. In this embodiment, the flat coil is sleeved on the "racetrack-shaped" winding post, or it can be sleeved on the "cylindrical" winding post.

[0066] When the structure of the winding post is "racetrack-shaped", the entire winding post is an elongated "cylindrical" winding post that is parallel to the side post, which makes the magnetic field lines more evenly distributed and the loss will not be concentrated at the edges of the winding post and the side post.

[0067] The magnetic element disclosed herein, when a flat coil is fitted onto two types of winding posts, maintains the same alternating magnetic flux density (Bac), that is, maintains the same operating state. Compared with a cylindrical winding post, when fitted onto a "racetrack-shaped" winding post, the efficiency can be optimized by 0.4% for low-frequency winding and 0.66% for high-frequency winding.

[0068] In some embodiments of this invention, an inductor is also provided, which includes the aforementioned magnetic element.

[0069] In some embodiments of this invention, a transformer is also provided, which includes the aforementioned magnetic element.

[0070] In one possible embodiment, the magnetic element in this disclosure can be used in a 45W-140W miniaturized adapter.

[0071] In the embodiments disclosed herein, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The concepts of "first," "second," etc., mentioned in this disclosure are only used to distinguish different devices, modules, or units and are not used to define the order of functions performed by these devices, modules, or units or their interdependencies.

[0072] In this disclosure, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0073] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the utility model disclosed herein.

[0074] This disclosure is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The description and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

Claims

1. A magnetic element, characterized in that, include: A magnetic core, a flat coil, the magnetic core including a winding post, the flat coil being sleeved on the winding post; The flat coil has an SPS structure; The flat coil includes: a bottom layer, a bottom shielding layer, a primary main coil, a top shielding layer, and a top layer, wherein the primary main coil is located between the top shielding layer and the bottom shielding layer, and the primary main coil, the top shielding layer, and the bottom shielding layer are all located between the top layer and the bottom layer. The bottom shielding layer and the top shielding layer include: a shielding coil; the bottom secondary layer and the top secondary layer include: a secondary coil; The primary coil in the flat coil includes a primary main coil and a shielding coil.

2. The magnetic element according to claim 1, characterized in that, The magnetic core further includes a first side post and a second side post arranged opposite to each other, and the winding post is located between the first side post and the second side post. The edges of the first side post and the second side post are parallel to each other along a first direction. The length of the winding post is greater than its width, and the length direction of the winding post is the same as the first direction.

3. The magnetic element according to claim 1, characterized in that, The bottom shielding layer and / or top shielding layer also include: a primary auxiliary winding.

4. The magnetic element according to claim 1, characterized in that, The bottom level and / or top level also include: a secondary auxiliary winding.

5. The magnetic element according to claim 1, characterized in that, One end of the shielding coil of the top shielding layer is connected to the static point, and the other end is connected to one end of the shielding coil of the bottom shielding layer. The other end of the shielding coil of the bottom shielding layer is connected to one end of the primary main coil, and the other end of the primary main coil is connected to the primary moving point.

6. The magnetic element according to claim 1, characterized in that, The thickness of the primary and secondary side insulation layers is set to 0.1-0.3mm.

7. The magnetic element according to claim 1, characterized in that, The ratio of the number of turns of the primary coil to the number of turns of the secondary coil is 7:

1.

8. The magnetic element according to claim 1, characterized in that, The primary coil has a copper thickness of 3 oz or 4 oz; the secondary coil has a copper thickness of 2 oz.

9. The magnetic element according to claim 1, characterized in that, The number of PCB layers for the magnetic element can be any one of 6, 8, 10, and 12.

10. An inductor, characterized in that, Includes the magnetic element as described in any one of claims 1 to 9.

11. A transformer, characterized in that, Includes the magnetic element as described in any one of claims 1 to 9.

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