Flat coupled inductor

Abstract

Flat coupled inductor (Z), comprising: - a magnetic core part (1) which is provided on its opposite sides with a first opening (1a) or at least a second opening (1b) and comprises the following: - a first magnetic core body (11) and - a second magnetic core body (12) connected to the first magnetic core body (11), wherein there is an accommodation space (S) between the first magnetic core body (11) and the second magnetic core body (12), which is connected to the first opening (1a) and the second opening (1b); - a first coil (2) comprising a first arc-shaped base body (20), a first pin (21), a second pin (22) and a third pin (23), the first arc-shaped base body (20) having a first receiving space (S1) and being located in the housing space (S), the first pin (21) being connected to the first arc-shaped base body (20) and extending out of the first opening (1a) in a direction away from the first magnetic core body (11), while the second pin (22) and the third pin (23) are each connected to the first arc-shaped base body (20) and extending out of the second opening (1b) in a direction away from the first magnetic core body (11); and - a second coil (3) comprising a second arc-shaped base body (31) and two inner pins (32), wherein the second arc-shaped base body (31) has a second receiving space (S2) and is arranged in the first receiving space (S1), while each of the inner pins (32) is connected to the second arc-shaped base body (31), extends out of the second opening (1b) in a direction away from the first magnetic core body (11) and is located between the second pin (22) and the third pin (23).

Description

[0001] The present utility model relates to an inductor structure, in particular to a flat coupled inductor.

[0002] Inductors function to filter noise, suppress instantaneous currents, attenuate electromagnetic interference, and convert power. They have a wide range of applications and are used in electronics in transformers, energy storage devices, sensors, induction motors, filters, and electromagnetic relays.

[0003] Inductors known from the prior art have a large overall height, which limits their application range. Furthermore, inductive elements must exhibit high dielectric strength and high power density to meet user requirements.

[0004] Therefore, the question of how the aforementioned shortcomings can be overcome by improving the structural design has become an important issue that needs to be addressed in this field.

[0005] Starting from the disadvantages of the prior art, the present utility model aims to offer a flat coupled inductor.

[0006] To solve this problem, the present utility model proposes a flat coupled inductor comprising a magnetic core section, a first coil, and a second coil. The magnetic core section is provided with a first opening and a second opening, respectively, on opposite sides and comprises a first magnetic core body and a second magnetic core body. The second magnetic core body is connected to the first magnetic core body, with a housing space between the first and second magnetic core bodies being connected to the first and second openings. The first coil comprises a first arc-shaped base body, a first pin, a second pin, and a third pin. The first arc-shaped base body has a first receiving space and is located within the housing space.The first pin is connected to the first arc-shaped base body and extends from the first opening in a direction away from the first magnetic core body. The second and third pins are each connected to the first arc-shaped base body and extend from the second opening in a direction away from the first magnetic core body. The second coil comprises a second arc-shaped base body and two inner pins. The second arc-shaped base body has a second receiving space and is positioned within the first receiving space, with a gap between the second arc-shaped base body and the first arc-shaped base body. Each of the inner pins is connected to the second arc-shaped base body, extends from the second opening in a direction away from the first magnetic core body, and is located between the second and third pins. Fig. Figure 1 shows a three-dimensional schematic representation of a flat coupled inductor of an embodiment of the present utility model. Fig. Figure 2 shows a three-dimensional schematic representation of the in Fig. 1. Example shown. Fig. Figure 3 shows a three-dimensional schematic representation of the in Fig. 1. Example shown. Fig. Figure 4 shows a schematic exploded view of the [unclear text]. Fig. 1. Example shown. Fig. Figure 5 shows a schematic exploded view of the [unclear text]. Fig. 1. Example shown. Fig. Figure 6 shows a top view of the in Fig. 1. Exemplary embodiment shown without the first magnetic core body. Fig. Figure 7 shows a view from below of the in Fig. 1. Exemplary embodiment shown without the second magnetic core body.

[0007] It will be directed to the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7. Referenced, whereby Fig. 1 a three-dimensional schematic representation of a flat coupled inductor Z of an embodiment of the present utility model, Fig. 2 a three-dimensional schematic representation of the in Fig. 1 shown embodiment, Fig. 3 a three-dimensional schematic representation of the in Fig. 1 shown embodiment, Fig. 4 a schematic exploded view of the in Fig. 1 shown embodiment, Fig. 5 a schematic exploded view of the in Fig. 1 shown embodiment, Fig. 6 a top view of the in Fig. 1 illustrated embodiment without the first magnetic core body and Fig. 7 a view from below of the in Fig. Figure 1 shows an embodiment without the second magnetic core body.

[0008] The flat coupled inductor Z comprises a magnetic core section 1, a first coil 2, and a second coil 3. The magnetic core section 1 is provided on its opposite sides with a first opening 1a and a second opening 1b, respectively, and comprises a first magnetic core body 11 and a second magnetic core body 12. The second magnetic core body 12 is connected to the first magnetic core body 11, with a space S between the first magnetic core body 11 and the second magnetic core body 12, which is connected to the first opening 1a and the second opening 1b. The first coil 2 comprises a first arc-shaped base body 20, a first pin 21, a second pin 22, and a third pin 23.

[0009] The first arc-shaped base body 20 has a first receiving space S1 and is located in the housing space S. The first pin 21 is connected to the first arc-shaped base body 20 and extends out of the first opening 1a in a direction away from the first magnetic core body 11. The second pin 22 and the third pin 23 are each connected to the first arc-shaped base body 20 and extend out of the second opening 1b in a direction away from the first magnetic core body 11. The second coil 3 comprises a second arc-shaped base body 31 and two inner pins 32. The second arc-shaped base body 31 has a second receiving space S2 and is arranged in the first receiving space S1, with a gap between the second arc-shaped base body and the first arc-shaped base body 20.Each of the inner pins 32 is connected to the second arc-shaped base body 31, extends out of the second opening 1b in a direction away from the first magnetic core body 11, and is located between the second pin 22 and the third pin 23. In this embodiment, the first pin 21, the second pin 22, and the third pin 23 also protrude from a bottom surface 122 of the second magnetic core body 12.

[0010] The aforementioned arc shape can be in the shape of a “⊓” or a “C”. According to some embodiments, the arc shape is an “Ω” shape. According to some embodiments, the first magnetic core body 11 and the second magnetic core body 12 (i.e., the magnetic core part 1) can be made of ferrite or a soft magnetic material. According to some embodiments, the first coil 2 and the second coil 3 can be flat coils, but are not limited to this. The first coil 2 and the second coil 3 can also be made of stamped copper sheets or other conductive materials. The first coil 2 and the second coil 3 are insulated from each other, for example, by not being in physical contact with each other (which is achieved, for example, by the presence of a gap G1 between the first arc-shaped base body 20 and the second arc-shaped base body 31, as described in Fig. 6 and Fig. Figure 7 shows the shape of a "⊓"-shaped channel). By providing, for example, the gap G1 and further gaps (see below), ultra-high voltage withstand capability is achieved. The size of the gap G1 can be flexibly adjusted by the manufacturer or the user according to the actual requirements, whereby changing the size of the gap G1 controls the magnitude of the first inductance generated by the first coil 2 and the second inductance generated by the second coil 3.

[0011] As in Fig. 4 and Fig. As shown in Figure 5, the first arc-shaped base body 20 of the flat coupled inductor Z comprises two legs 201 and a web 202, the web 202 being connected to the legs 201 at both of its ends, while the first pin 21 is connected to the middle of the web 202.

[0012] As in Fig. 2, Fig. 3, Fig. 4 to Fig. As shown in Figure 5, each of the inner pins 32 of the flat coupled inductor Z comprises an extension section 321 and a solder pad 322, wherein the solder pad 322 is connected to the extension section 321 and is located below the second magnetic core body 12. Such a configuration contributes to realizing a flat design of the flat coupled inductor Z, thereby reducing the overall height of the flat coupled inductor Z. According to some embodiments, the flat coupled inductor Z has a height of 3-6 millimeters (mm) in the vertical direction. In the embodiment shown in Fig. In the embodiment shown in Figure 2, there is a distance G2 between the solder pad 322 and the second magnetic core body 12 of the flat coupled inductor Z.

[0013] In the Fig. In the embodiment shown in Figure 1, the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32 of the flat coupled inductor Z extend in the same direction. However, the present utility model is not limited to this. According to some other embodiments, at least one of the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32 extends in one direction, and at least one of the remaining pins extends in another direction. At least one of the pins can extend in a different direction, with, for example, the first pin 21, the second pin 22, and the third pin 23 extending downwards (towards the second magnetic core body 12), while the two inner pins 32 extend upwards (towards the first magnetic core body 11).In some other embodiments, the first pin 21, the second pin 22, and the third pin 23 extend upwards (towards the first magnetic core body 11), and the two inner pins 32 extend downwards (towards the second magnetic core body 12). The direction of extension of the pins is not restricted within the scope of this utility model and can be adapted according to the user's requirements. According to some embodiments, the power density of the inductor can be increased by increasing the extension length of the pins (i.e., the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32), thus allowing a variety of components to be placed below the magnetic core body 1.

[0014] According to some embodiments, the second opening 1b is only present once, with the second pin 22, the third pin 23, and the two inner pins 32 protruding from the second opening 1b. In the embodiment shown in Fig. In the embodiment shown in Figure 3, the second opening 1b is provided in a number of two, with the second pin 22 protruding from one of the second openings 1b and the third pin 23 protruding from the other second opening 1b. Furthermore, the two inner pins 32 each protrude from their respective second opening 1b and are located between the second pin 22 and the third pin 23. The second pin 22 and its associated inner pin 32 form a notch O, and the third pin 23 and its associated inner pin 32 form another notch O.

[0015] The construction of the first magnetic core body 11 of the flat coupled inductor Z is discussed in more detail. As in Fig.As shown in Figure 5, the first magnetic core body 11 comprises a first plate 111 and a projection 112, wherein the two sides of the first plate 111, corresponding to the first opening 1a and the second opening 1b respectively, are defined as first side 111a and second side 111b. The projection 112 is connected to a surface of the first plate 111 facing the second magnetic core body 12 and is located in the second receiving space S2. In this embodiment, the first magnetic core body 11 of the flat coupled inductor Z further comprises two wall columns 113, each connected to the surface of the first plate 111, extending from the first opening 1a to the second opening 1b, and arranged on both sides of the projection 112, with each of the wall columns 113 being flush with the first side 111a of the first plate 111 at one end. The other end of the wall columns 113 does not reach the second side 111b of the first plate 111.

[0016] The construction of the second magnetic core body 12 of the flat coupled inductor Z is described in more detail. The second magnetic core body 12 of the flat coupled inductor Z comprises a second plate 121, which is provided on one side with a hole 1211, which is part of the first opening 1a, and on the opposite side with a projection 1212, which is located between the two inner pins 32.

[0017] One of the advantageous effects of the present utility model is that, in the flat coupled inductor according to the present utility model, the technical solutions "the first coil comprises a first arc-shaped base body, a first pin, a second pin and a third pin", "the first arc-shaped base body has a first receiving space and is located in the housing space, wherein the first pin is connected to the first arc-shaped base body and extends out of the first opening in a direction away from the first magnetic core body, while the second pin and the third pin are each connected to the first arc-shaped base body and extend out of the second opening in a direction away from the first magnetic core body", "the second coil comprises a second arc-shaped base body and two inner pins,which second arc-shaped base body has a second receiving space and is arranged in the first receiving space, each of the inner pins being connected to the second arc-shaped base body and extending out of the second opening in a direction away from the first magnetic core body” and “the two inner pins are located between the second pin and the third pin” the height of the inductor can be reduced to achieve high dielectric strength and high power density.

[0018] In addition, the flat coupled inductor Z of the present utility model achieves a very high coupling coefficient and mutual interaction between two coupled inductors through a well-designed magnetic circuit. Furthermore, high dielectric strength is achieved through the design of the gap between the first and second coils and the size of the distance between them and the first or second magnetic core body (e.g., the distance between the solder pad and the second magnetic core body described above). Depending on the combination of the magnetic core part, the first coil, and the second coil of the present utility model, the height of the coupled inductor can be reduced to meet the requirements of the respective application.

[0019] Furthermore, according to one embodiment, by increasing the height of the pins (i.e., the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32), a variety of components (e.g., on a printed circuit board) can be added below the second magnetic core body, which not only facilitates the reduction of the inductor's height but also contributes to increasing the power density of the overall product.

Claims

[1] Flat coupled inductor (Z), comprising: - a magnetic core part (1) which is provided on its opposite sides with a first opening (1a) or at least a second opening (1b) and comprises the following: - a first magnetic core body (11) and - a second magnetic core body (12) connected to the first magnetic core body (11), wherein there is an accommodation space (S) between the first magnetic core body (11) and the second magnetic core body (12), which is connected to the first opening (1a) and the second opening (1b); - a first coil (2) comprising a first arc-shaped base body (20), a first pin (21), a second pin (22) and a third pin (23), the first arc-shaped base body (20) having a first receiving space (S1) and being located in the housing space (S), the first pin (21) being connected to the first arc-shaped base body (20) and extending out of the first opening (1a) in a direction away from the first magnetic core body (11), while the second pin (22) and the third pin (23) are each connected to the first arc-shaped base body (20) and extending out of the second opening (1b) in a direction away from the first magnetic core body (11); and - a second coil (3) comprising a second arc-shaped base body (31) and two inner pins (32), wherein the second arc-shaped base body (31) has a second receiving space (S2) and is arranged in the first receiving space (S1), while each of the inner pins (32) is connected to the second arc-shaped base body (31), extends out of the second opening (1b) in a direction away from the first magnetic core body (11) and is located between the second pin (22) and the third pin (23). [2] Flat coupled inductor (Z) according to claim 1, wherein the first arc-shaped base body (20) comprises two legs (201) and a web (202), the web (202) being connected to the legs (201) at both ends, while the first pin (21) is connected to the web (202) in the middle of the web (202). [3] Flat coupled inductor (Z) according to claim 1, wherein the first pin (21), the second pin (22), the third pin (23) and the two inner pins (32) extend in the same direction. [4] Flat coupled inductor (Z) according to claim 1, wherein at least one of the first pin (21), the second pin (22), the third pin (23) and the two inner pins (32) extends in one direction and at least one of the remaining pins extends in another direction. [5] Flat coupled inductor (Z) according to claim 1, wherein each of the inner pins (32) comprises an extension section (321) and a solder pad (322), the solder pad (322) being connected to the extension section (321) and being located below the second magnetic core body (12) at a distance therefrom. [6] Flat coupled inductor (Z) according to claim 1, wherein the second opening (1b) is provided in a number of two, each of the inner pins (32) protruding from the respective associated second opening (1b). [7] Flat coupled inductor (Z) according to claim 1, wherein the second pin (22) forms a notch (O) with the associated inner pin (32) and the third pin (23) forms a further notch (O) with the associated inner pin (32). [8] Flat coupled inductor (Z) according to claim 1, wherein the first magnetic core body (11) comprises a first plate (111) and a protrusion (112), wherein the two sides of the first plate (111) that are associated with the first opening (1a) and the second opening (1b) respectively are defined as the first side (111a) and second side (111b), respectively, while the protrusion (112) is connected to a surface of the first plate (111) facing the second magnetic core body (12) and is located in the second receiving space (S2). [9] Flat coupled inductor (Z) according to claim 8, wherein the first magnetic core body (11) further comprises two wall columns (113) which are each connected to the surface, extend from the first opening (1a) to the second opening (1b) and are arranged on both sides of the protrusion (112), wherein each of the wall columns (113) terminates flush with the first side (111a) of the first plate (111) at one end. [10] Flat coupled inductor (Z) according to claim 7, wherein the second magnetic core body (12) comprises a second plate (121) which is provided on one side with a hole (1211) which is part of the first opening (1a) and on the opposite side with a projection (1212) which is located between the two inner pins (32).

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