Coupled magnetic element and coupled magnetic module with high voltage resistance and high power density

Abstract

Coupled magnetic element with high dielectric strength and high power density (1), comprising: - a first magnetic core (11) comprising a receiving chamber (S1) extending continuously between two opposing surfaces; - an outer coil (13) which is removably arranged within the receiving chamber (S1) and comprises two first side columns (131) and a first connecting section (132), wherein the first connecting section (132) is connected at both ends to the upper ends of the two first side columns (131) and forms a receiving space (S2) with the two first side columns (131); - an inner coil (14) which is removably arranged within the receiving space (S2) and comprises two second side columns (141), a second connecting section (142) and two lower connecting leg sections (143), wherein the two ends of the second connecting section (142) are each connected to the upper ends of the two second side columns (141), while the lower end of each of the second side columns (141) is connected to one of the lower connecting leg sections (143), wherein the second side columns (141), the second connecting section (142) and the two lower connecting leg sections (143) form a housing space (S3); and - a second magnetic core (12) which is removable and arranged within the accommodation space (S3).

Description

[0001] The present invention relates to a magnetic element, in particular a coupled magnetic element with high dielectric strength and high power density.

[0002] In current technology, electronic devices are evolving towards high efficiency and high power density. For example, in power supply devices, the inductors used are typically relatively large and take up a relatively large amount of space, which is why reducing the size of an inductor element has become an important topic in the relevant technology fields.

[0003] Conventional inductors are usually individual and separate components. To achieve high voltage withstand capability, their volume must be increased, or several small inductors must be connected in series across a conductive layer on a printed circuit board. However, this would require more space and hinders the miniaturization of electronic devices.

[0004] To overcome the shortcomings of the prior art, the present invention provides a coupled magnetic element with high dielectric strength and high power density, comprising a first magnetic core, an outer coil, an inner coil, and a second magnetic core. The first magnetic core has a receiving chamber extending continuously between two opposing surfaces. The outer coil is removably arranged within the receiving chamber and comprises two first side columns and a first connecting section, the two ends of the first connecting section being connected to the upper ends of the two first side columns. The first connecting section, together with the two first side columns, forms a receiving space.The inner coil is removably arranged within the receiving space and comprises two secondary side columns, a secondary connecting section, and two lower connecting leg sections, with the two ends of the secondary connecting section each being connected to the upper ends of the two secondary side columns, while the lower end of each of the secondary side columns is connected to one of the lower connecting leg sections. The secondary side columns, the secondary connecting section, and the two lower connecting leg sections form a housing. The second magnetic core is removably arranged within the housing.

[0005] The present invention further provides a coupled magnetic module with high dielectric strength and high power density, comprising two coupled magnetic elements with high dielectric strength and high power density. Two first magnetic cores are connected to each other to form an outer magnetic core. In the two inner coils, two adjacent lower connecting leg sections are connected to each other.

[0006] An advantageous effect of the present invention is that, according to some embodiments, the coupled magnetic element with high dielectric strength and high power density according to the present invention offers the technical effect of high dielectric strength and high power density. Fig. Figure 1 shows a schematic spatial view of a coupled magnetic element with high dielectric strength and high power density according to an embodiment of the present invention. Fig. Figure 2 shows a schematic exploded view of the [unclear text]. Fig. 1 illustrated embodiment, Fig. Figure 3 shows a schematic representation of an inner coil according to an embodiment of the present invention, Fig. Figure 4 shows a schematic representation of an inner coil according to an embodiment of the present invention. Fig. Figure 5 shows a schematic spatial view of a coupled magnetic module with high voltage strength and high power density according to an embodiment of the present invention. Fig. Figure 6 shows a schematic exploded view of the [unclear text]. Fig. 5 illustrated embodiment, Fig. Figure 7 shows a schematic representation of the connection of two inner coils according to an embodiment of the present invention and Fig. Figure 8 shows a schematic representation of the connection of two inner coils according to an embodiment of the present invention.

[0007] It will be directed to the Fig. 1 to 4 are referred to, whereby Fig. 1 A schematic spatial view of a coupled magnetic element with high dielectric strength and high power density 1 according to an embodiment of the present invention. Fig. 2 a schematic exploded view of the in Fig. 1 illustrated embodiment, Fig. 3 a schematic representation of an inner coil 14 according to an embodiment of the present invention and Fig. Figure 4 shows a schematic representation of an inner coil 14 according to an embodiment of the present invention. The difference between Fig. 3 and Fig. 4 lies in the different perspectives.

[0008] The coupled magnetic element with high dielectric strength and high power density 1 comprises a first magnetic core 11, an outer coil 13, an inner coil 14, and a second magnetic core 12. The first magnetic core 11 has a receiving chamber S1 extending continuously between two opposing surfaces. The outer coil 13 is removably arranged within the receiving chamber S1 and comprises two first side columns 131 and a first connecting section 132, the two ends of the first connecting section 132 being connected to the upper ends of the two first side columns 131. The first connecting section 132, together with the two first side columns 131, forms a receiving space S2.The inner coil 14 is removably arranged within the receiving space S2 and comprises two second side columns 141, a second connecting section 142, and two lower connecting leg sections 143, wherein the two ends of the second connecting section 142 are each connected to the upper ends of the two second side columns 141, while the lower end of each of the second side columns 141 is connected to one of the lower connecting leg sections 143. The second side columns 141, the second connecting section 142, and the two lower connecting leg sections 143 form a housing space S3. The second magnetic core 12 is removably arranged within the housing space S3.

[0009] As in Fig. 1 and Fig. As shown in Figure 2, each of the first side columns 131 comprises a column body 1311 and a connecting leg 1312, wherein the connecting leg 1312 is arranged at the lower end of the column body 1311, extends to the outside of the column body 1311 and protrudes from the first magnetic core 11.

[0010] As in Fig. As shown in Figures 2 to 4, each lower connecting leg section 143 of the inner coil 14 comprises a base body 1431 and a base body 1432, the base body 1431 being connected to the base body 1432. The two base bodies 1432 are arranged opposite each other and are located outside the two second side columns 141. Each base body 1431 has a side edge 1431a and a beveled edge 1431b, each side edge 1431a being connected to one of the second side columns 141, while a slot G is provided between the two beveled edges 1431b. According to some embodiments, the base body 1431 has a geometric shape, with a slot G provided between the mating base bodies 1431.For example, in this embodiment, the base body 1431 essentially has the shape of a right-angled triangle, the three sides of which consist of the oblique edge 1431b, the lateral edge 1431a, and a base edge, the base edge being connected to the base body 1432 (and thus forming an integral unit). According to some embodiments, the width of the slot G (i.e., the distance between the two oblique edges 1431b) is in the range of 0.1 mm to 0.5 mm.

[0011] It will be discussed again Fig. 1 referred. According to the in Fig. In the embodiment shown in Figure 1, the connecting legs 1312 can be located between two opposing base bodies 1432 and assigned to the two base bodies 1432.

[0012] The first magnetic core 11 and the second magnetic core 12 can be made of ferrite or a soft magnetic material. The first magnetic core 11 can, for example, be square. The second magnetic core 12 can, for example, be cube-shaped. The outer coil 13 is essentially in the shape of an arch. The outer coil 13 can be a flat coil, but is not limited to this. The outer coil 13 can also be made of stamped copper sheet or other types of conductive materials. The inner coil 14 can be partially enclosed by the outer coil 13. The two second side columns 141 and the second connecting section 142 of the inner coil 14 together have approximately the shape of another arch. The inner coil 14 can be a flat coil, but is not limited to this. The inner coil 14 can also be made of stamped copper sheet or other types of conductive materials.

[0013] Furthermore, according to the in Fig. In the embodiment shown in Figures 1 to 4, the first magnetic core 11, the outer coil 13, and the second magnetic core 12 form a first inductor, while the first magnetic core 11 together with the inner coil 14 and the second magnetic core 12 form a second inductor. The gap between the first magnetic core 11 and the second magnetic core 12 forms an air gap. The first magnetic core 11 and the outer coil 13 can be in direct contact or not in contact (i.e., isolated from each other). The second magnetic core 12 and the outer coil 13 can be in contact or not in contact. The second magnetic core 12 and the inner coil 14 can also be in contact or not in contact. The outer coil 13 and the inner coil 14 are isolated from each other.By controlling the contact relationships between the aforementioned elements and the air gap configuration, the magnetic path and coupling strength can be effectively adjusted, thereby controlling the inductance. Simultaneously, the coil winding method and magnetic core design disclosed in this utility model allow for a shorter conductor path and a reduction in DC resistance (DCR), resulting in extremely low DCR values ​​and thus increasing the efficiency and overall power density of the inductor element.

[0014] Furthermore, in some embodiments of the coupled magnetic element with high dielectric strength and high power density of the present utility model, the first magnetic core 11, the outer coil 13, the inner coil 14 and the second magnetic core 12 can also be in contact with each other in isolation, thereby enabling a magnetic element structure with extremely high dielectric strength.

[0015] It will be directed to the Fig. 5 to 8 and again on Fig. 2. Referenced, whereby Fig. 5 a schematic spatial view of a coupled magnetic module with high dielectric strength and high power density Z according to an embodiment of the present invention, Fig. 6 a schematic exploded view of the in Fig. 5 illustrated embodiment, Fig. 7 in schematic representation the connection of two inner coils 14 according to an embodiment of the present invention and Fig. Figure 8 shows a schematic representation of the connection of two inner coils 14 according to an embodiment of the present invention. The difference between Fig. 7 and Fig. 8 lies in the different perspectives.

[0016] The coupled high-voltage-strength, high-power-density magnetic module Z comprises two coupled high-voltage-strength, high-power-density magnetic elements 1. As shown in Fig. As shown in Figure 5, two first magnetic cores 11 are connected to each other to form an outer magnetic core 100, which, according to some embodiments, is formed in one piece. The connecting leg 1312 of the first side column 131 is arranged at the lower end of the column body 1311 (see Figure 5). Fig. 2), extends to the outside of the column body 1311 and protrudes from the outer magnetic core 100.

[0017] In the two inner coils 14 of the coupled high-voltage-strength, high-power-density magnetic module, two adjacent lower connecting leg sections 143 are connected to each other. As in Fig.As shown in Figure 8, the two lower connecting leg sections 143 are connected to each other via two base bodies 1432, wherein the two base bodies 1432 are defined as a common base body 1430 after the connection is made, which, according to some embodiments, is formed in one piece. It should be noted that the dimensions of the two outer base bodies 1432 may be identical or not identical. In some embodiments, the dimensions of the common base body 1430 also differ from those of the outer base bodies 1432; for example, they may be larger or smaller than those of the outer base bodies 1432.The structural design of the common base body 1430 not only improves the mechanical stability and reliability of the electrical conductivity between the internal coils 14, but also effectively shortens the current conduction path and reduces the contact resistance, thereby reducing the DC resistance (DCR) and increasing the overall efficiency and power density of the module. [Advantageous effects of the exemplary embodiments]

[0018] An advantageous effect of the present invention is that, according to some embodiments, the coupled magnetic element with high dielectric strength and high power density according to the present invention offers the technical effect of high dielectric strength and high power density.

[0019] Furthermore, according to some embodiments, the coupled magnetic element with high dielectric strength and high power density of the present invention achieves a high coupling coefficient between the two inductors through an optimized magnetic circuit design. This enables mutual interaction between the inductors, which contributes to increasing energy conversion efficiency. Simultaneously, several air gaps are provided between the first and second magnetic cores, which not only effectively improve the dielectric strength but also allow for adjustment of the magnetic flux distribution and inductance values ​​as required. In addition, the present invention, through its special coil winding method and the structural design of the common base body, effectively shortens the current path and reduces conductor losses, thereby achieving an extremely low DC resistance (DCR).Through the comprehensive design described above, the present invention can overcome the technical limitations of existing high-voltage-strength, high-power-density magnetic elements on the market, while simultaneously achieving the advantage of reduced DC resistance, which helps to reduce the volume of electronic devices and meet the requirements for high efficiency and miniaturization.

[0020] In other words, the first magnetic core, together with the outer coil and the second magnetic core, forms the first inductor, while the first magnetic core, together with the inner coil and the second magnetic core, forms the second inductor. The inductance value between the two inductors is adjusted across the air gap to meet the requirements of the respective circuit. According to some embodiments, the coupled magnetic element of the present utility model enables the one-piece integration of two inductor elements. This not only effectively reduces the number and space required for elements in a printed circuit board assembly (PCBA), but also shortens the current path, lowers the contact resistance, and reduces the overall DC resistance.On the other hand, the present utility model also maximizes space utilization and power density, enables miniaturization of the product and high efficiency, and thus effectively solves the challenges faced by the state of the art.

[0021] Since the coupled magnetic module with high voltage strength and high power density contains the coupled magnetic element with high voltage strength and high power density described above, it naturally has the technical advantages of the coupled magnetic element with high voltage strength and high power density described above. Reference symbol list Z-coupled magnetic module with high voltage resistance and high power density 1 Coupled magnetic element with high voltage strength and high power density 100 external magnet core 11 First magnetic core 12 Second magnetic core 13 Outer coil 131 First side column 1311 Column bodies 1312 Connecting leg 132 First connecting section 14 inner coil 141 Second side column 142 Second connecting section 143 Lower connecting leg section 1430 Common Base Body 1431 Basic body 1431a Side edge 1431b Slanted edge 1432 Base bodies G slot S1 Admission Chamber S2 Recording Room S3 Accommodation Room

Claims

[1] Coupled magnetic element with high dielectric strength and high power density (1), comprising: - a first magnetic core (11) comprising a receiving chamber (S1) extending continuously between two opposing surfaces; - an outer coil (13) which is removably arranged within the receiving chamber (S1) and comprises two first side columns (131) and a first connecting section (132), wherein the first connecting section (132) is connected at both ends to the upper ends of the two first side columns (131) and forms a receiving space (S2) with the two first side columns (131); - an inner coil (14) which is removably arranged within the receiving space (S2) and comprises two second side columns (141), a second connecting section (142) and two lower connecting leg sections (143), wherein the two ends of the second connecting section (142) are each connected to the upper ends of the two second side columns (141), while the lower end of each of the second side columns (141) is connected to one of the lower connecting leg sections (143), wherein the second side columns (141), the second connecting section (142) and the two lower connecting leg sections (143) form a housing space (S3); and - a second magnetic core (12) which is removable and arranged within the accommodation space (S3). [2] Coupled magnetic element with high dielectric strength and high power density (1) according to claim 1, wherein each of the first side columns (131) comprises a column body (1311) and a connecting leg (1312), the connecting leg (1312) being arranged at the lower end of the column body (1311), extending to the outside of the column body (1311) and projecting out of the first magnetic core (11). [3] Coupled magnetic element with high dielectric strength and high power density (1) according to claim 1 or 2, wherein each of the lower connecting leg sections (143) comprises a base body (1431) and a base body (1432), the base body (1431) being connected to the base body (1432), the two base bodies (1432) being arranged opposite each other and each being located outside the two second side columns (141), and wherein each of the base bodies (1431) has a side edge (1431a) and an inclined edge (1431b), each of the side edges (1431a) being connected to one of the second side columns (141), while a slot (G) is provided between the two inclined edges (1431b). [4] Coupled magnetic element with high dielectric strength and high power density (1) according to claim 3, wherein each of the first side columns (131) comprises a column body (1311) and a connecting leg (1312), wherein the connecting leg (1312) is arranged at the lower end of the column body (1311), extends to the outside of the column body (1311) and protrudes from the first magnetic core (11), and wherein each of the connecting legs (1312) is located between and associated with two opposing base bodies (1432). [5] Coupled magnetic element with high dielectric strength and high power density (1) according to claim 3 or 4, wherein the base body (1431) is essentially in the shape of a right-angled triangle, the three sides of which consist of the oblique edge (1431b), the side edge (1431a) and a base edge, wherein the base edge is connected to the base body (1432). [6] Coupled high-voltage-strength, high-power-density (Z) magnetic module comprising: - two coupled magnetic elements with high dielectric strength and high power density (1) according to claim 1; wherein the first two magnetic cores (11) are connected to each other to create an outer magnetic core (100); and wherein in the two inner coils (14) two adjacent lower connecting leg sections (143) are connected to each other. [7] Coupled magnetic module with high dielectric strength and high power density (Z) according to claim 6, wherein each of the first side columns (131) comprises a column body (1311) and a connecting leg (1312), the connecting leg (1312) being arranged at the lower end of the column body (1311), extending to the outside of the column body (1311) and protruding from the outer magnet core (100). [8] Coupled magnetic module with high dielectric strength and high power density (Z) according to claim 6 or 7, wherein each of the lower connecting leg sections (143) comprises a base body (1431) and a base body (1432), the base body (1431) being connected to the base body (1432), the two base bodies (1432) being arranged opposite each other and each being located outside the two second side columns (141), and wherein each of the base bodies (1431) has a side edge (1431a) and an inclined edge (1431b), each of the side edges (1431a) being connected to one of the second side columns (141), while a slot (G) is provided between two adjacent inclined edges (1431b). [9] Coupled magnetic module with high dielectric strength and high power density (Z) according to claim 8, wherein each of the first side columns (131) comprises a column body (1311) and a connecting leg (1312), wherein the connecting leg (1312) is arranged at the lower end of the column body (1311), extends to the outside of the column body (1311) and protrudes from the outer magnet core (100), and wherein each of the connecting legs (1312) is located between two adjacent base bodies (1432) and is associated with the two adjacent base bodies (1432). [10] Coupled magnetic module with high dielectric strength and high power density (Z) according to claim 8 or 9, wherein each of the base bodies (1431) is essentially in the shape of a right-angled triangle, the three sides of which consist of the oblique edge (1431b), the side edge (1431a) and a base edge, the base edge being connected to the base body (1432).

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