Magnetic element

Abstract

A magnetic element according to an embodiment may comprise: a core unit including a first core and a second core disposed to face the first core in a first direction; a bobbin unit at least partially disposed in the core unit; and a coil unit including an upper coil and a lower coil disposed in the bobbin unit, wherein the upper coil and the lower coil are spaced apart from each other in the first direction.

Description

[Technical Field]

[0001] Embodiments relate to a magnetic element.[Background Art]

[0002] Various magnetic coupling devices, such as a transformer or a line filter, namely, a magnetic element, are incorporated into power supply devices for electronic equipment.

[0003] The transformer may be included in electronic equipment for various purposes. For example, the transformer may be used to perform an energy transfer function of transferring energy from one circuit to another. In addition, the transformer may be used to perform a step-up or step-down function of changing the magnitude of voltage. In addition, the transformer, which features only inductive coupling between the primary and secondary windings, thus directly forming no DC path, may be used for DC blocking and AC passing or for insulating separation between two circuits.

[0004] For a 20-kW large-capacity transformer, various cooling methods are used to dissipate heat generated from a coil and a core. For example, heat may be dissipated using air cooling with a fan. However, insufficient air inflow into the transformer may cause an issue with heat dissipation performance, and therefore research is ongoing to address this.[Disclosure][Technical Problem]

[0005] Embodiments provide a magnetic element with excellent cooling performance.[Technical Solution]

[0006] A magnetic element according to an embodiment may include a core unit including a first core and a second core disposed opposite the first core in a first direction, a bobbin unit at least partially disposed in the core unit, and a coil unit including an upper coil and a lower coil disposed on the bobbin unit, wherein the upper coil and the lower coil may be disposed spaced apart from each other in the first direction.

[0007] For example, each of the first and second cores may include a first body portion, a first outer leg portion protruding from one end of the first body portion in the first direction and extending in a second direction intersecting the first direction, a second outer leg portion protruding from the other end of the first body portion in the first direction and extending in the second direction, and a central leg portion protruding between the first outer leg portion and the second outer leg portion in the first direction and extending in the second direction.

[0008] For example, at least a part of the upper coil may be disposed between each of the first and second outer leg portions and the central leg portion of the first core, and at least a part of the lower coil may be disposed between each of the first and second outer leg portions and the central leg portion of the second core.

[0009] For example, the bobbin unit may include a second body portion on which the upper coil and the lower coil are disposed spaced apart from each other in the first direction, a first upper protrusion protruding from an upper end of the second body portion in a third direction intersecting each of the first and second directions, and a first lower protrusion protruding from a lower end of the second body portion in the third direction.

[0010] For example, the first upper protrusion may include a 1-1 upper protrusion disposed between the first outer leg portion and the central leg portion of the first core and a 1-2 upper protrusion disposed between the second outer leg portion and the central leg portion of the first core, the 1-2 upper protrusion being located on the opposite side of the 1-1 upper protrusion in the third direction.

[0011] For example, the first lower protrusion may include a 1-1 lower protrusion disposed between the first outer leg portion and the central leg portion of the second core and a 1-2 lower protrusion disposed between the second outer leg portion and the central leg portion of the second core, the 1-2 lower protrusion being located on the opposite side of the 1-1 lower protrusion in the third direction.

[0012] For example, the bobbin unit may further include a coil support portion protruding from the second body portion between the first upper protrusion and the first lower protrusion in a horizontal direction, the coil support portion being configured to support the upper coil.

[0013] For example, the first upper protrusion and the first lower protrusion may overlap each other in the first direction.

[0014] For example, the second body portion may include a first through-hole formed through the second body portion in the first direction, and the central leg portion of each of the first and second cores may be inserted into and disposed in the first through-hole.

[0015] For example, the first through-hole may have a first length in the first direction, the central leg portion of the first core may have a second length in the first direction, the central leg portion of the second core may have a third length in the first direction, and the sum of the second length and the third length may be less than the first length.

[0016] For example, the bobbin unit may include a second through-hole formed through the second body portion in the horizontal direction, and the second through-hole may overlap the space between the upper coil and the lower coil in the third direction.

[0017] For example, the length of the second through-hole in the first direction may be greater than the length of the space in the first direction.

[0018] For example, the second body portion may include an upper area between the first upper protrusion and the second through-hole and a lower area between the second through-hole and the first lower protrusion, the upper coil may overlap the upper area in the third direction, and the lower coil may overlap the lower area in the third direction.

[0019] For example, the second body portion may include first and second side portions opposite each other in the third direction with the first through-hole interposed therebetween and third and fourth side portions opposite each other in the second direction with the first through-hole interposed therebetween, the third and fourth side portions being located between the first side portion and the second side portion, and each of the first and second side portions may have a larger length than each of the third and fourth side portions in the horizontal direction.

[0020] For example, the second through-hole may include 2-1 through-holes disposed in each of the first and second side portions and 2-2 through-holes disposed in each of the third and third side portions.

[0021] For example, the number of the 2-1 through-holes may be greater than the number of the 2-2 through-holes.

[0022] For example, the bobbin unit may include a first lower central protrusion protruding from the lower end of the third side portion of the second body portion in the first and second directions, a first lower peripheral protrusion protruding from one end of the first lower protrusion in the first and second directions and disposed on the periphery of the first lower central protrusion, a second lower central protrusion protruding from the lower end of the fourth side portion of the second body portion in the first and second directions, and a second lower peripheral protrusion protruding from the other end of the first lower protrusion in the first and second directions and disposed on the periphery of the second lower central protrusion.

[0023] For example, a bottom surface of each of the first and second lower central protrusions and the first and second lower peripheral protrusions and a bottom surface of the first body portion of the second core may be disposed on the same horizontal plane.

[0024] For example, the thickness of each of the first and second lower central protrusions and the first and second lower peripheral protrusions in the first direction may be the same as the thickness of the first body portion of the second core in the first direction.

[0025] For example, each of the first and second lower peripheral protrusions may have a step.

[0026] For example, each of the first and second lower peripheral protrusions may include a stepped portion recessed in the first direction and having a third through-hole.

[0027] For example, first and second wires drawn out respectively from both ends of the lower coil may be supported by the second lower peripheral protrusion, and the second lower peripheral protrusion may have a larger surface area than the first lower peripheral protrusion.

[0028] For example, third and fourth wires drawn out respectively from both ends of the upper coil may overlap the first lower peripheral protrusion in the first direction.

[0029] For example, the first body portion of the second core may be received in a first space between the first lower central protrusion and the second lower central protrusion and a second space between the first lower peripheral protrusion and the second lower peripheral protrusion.

[0030] For example, the upper coil may be a primary coil, and the lower coil may be a secondary coil.

[0031] For example, the lower coil may be a primary coil, and the upper coil may be a secondary coil.

[0032] For example, the distance between the upper coil and the lower coil in the first direction may be 1 mm to 2 mm.[Advantageous Effects]

[0033] A magnetic element according to embodiments has excellent cooling performance and heat dissipation performance.[Description of Drawings]

[0034] FIG. 1 is an assembled perspective view of a magnetic element according to an embodiment. FIG. 2 is an exploded perspective view of the magnetic element shown in FIG. 1. FIG. 3 is a perspective view of the magnetic element shown in FIG. 1 with a first core removed. FIG. 4 is a perspective view of the magnetic element shown in FIG. 1 with a core unit removed. FIGs. 5A to 5G are, respectively, an upper perspective view, a lower perspective view, a front view, a rear view, a plan view, a bottom view, and a side view of a bobbin unit shown in FIG. 2. FIG. 6 is a sectional view taken along line I-I' of FIG. 1. FIG. 7 is an assembled perspective view of a magnetic element according to another embodiment. FIG. 8 is an exploded perspective view of the magnetic element shown in FIG. 7. FIG. 9 is a perspective view of the magnetic element shown in FIG. 7 with a first upper core segment removed. FIG. 10 is a perspective view of the magnetic element shown in FIG. 7 with a first core removed. FIG. 11 is a perspective view of the magnetic element shown in FIG. 7 with the first core and a second lower core segment removed. FIG. 12 is an assembled perspective view of a magnetic element according to a yet another embodiment. FIG. 13 is an exploded perspective view of the magnetic element shown in FIG. 12. FIG. 14 is a perspective view of the magnetic element shown in FIG. 12 with first and second upper core segments removed. FIG. 15 is a perspective view of the magnetic element shown in FIG. 12 with a first core removed. FIG. 16 is a perspective view of the magnetic element shown in FIG. 12 with the first core and a first lower core segment removed. FIGs. 17A to 17C are, respectively, an upper perspective view, a plan view, and a front view of a bobbin shown in FIG. 13. FIG. 18A is a plan view of a right corner of the magnetic element shown in FIG. 12, FIG. 18B is a plan view of a left corner of the magnetic element shown in FIG. 12 with a second outer upper protrusion removed, FIG. 18C is a combined plan view of a coil unit and a second core, and FIG. 18D is a plan view of another embodiment of the right corner of the magnetic element shown in FIG. 12. FIG. 19A is a plan view of a magnetic element according to a further embodiment, and FIG. 19B is an enlarged view of part 'A' of FIG. 19A. FIGs. 20A and 20B are, respectively, a side view and a front view of the magnetic element shown in FIG. 12. FIG. 21A is a combined perspective view of the bobbin and a core unit of the magnetic element shown in FIG. 12, and FIG. 21B is a perspective view of the magnetic element shown in FIG. 21A with the first core removed. FIG. 22 is a combined perspective view of the core unit shown in FIG. 13. FIGs. 23A to 23C are plan views illustrating various outer upper protrusions of the magnetic element according to the embodiment. FIG. 24A is a lower assembled perspective view of the magnetic element shown in FIG. 23A, and FIG. 24B is a lower assembled perspective view of the magnetic element shown in FIGs. 19A and 23B. [Best Mode]

[0035] The present disclosure may be changed in various manners and may have various embodiments. Specific embodiments of the present disclosure will be described with reference to the drawings. However, the present disclosure is not limited to the specific embodiments, and it should be understood that the present disclosure includes all modifications, equivalents, or substitutions included in the idea and technical scope of the present disclosure.

[0036] Although terms including ordinal numbers, such as "first" and "second," may be used herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another component. For example, without departing from the scope of the present disclosure, a second component may be named a first component, and similarly, a first component may be named a second component. The term "and / or" includes any combination of a plurality of related listed items or any one of a plurality of related listed items.

[0037] It should be understood that, when a component is referred to as being "connected to" or "coupled to" another component, it may be directly connected to or coupled to another component or intervening components may be present. In contrast, it should be understood that, when a component is referred to as being "directly connected to" or "directly coupled to" another component, there are no intervening components present.

[0038] In the following description of the embodiments, it will be understood that, when an element, such as a layer (film), an area, a pattern, or a structure, is referred to as being "on" or "under" another element, such as a substrate, a layer (film), an area, a pad, or a pattern, it can be "directly" on or under another element or can be formed such that an intervening element is also present. Reference to on / above or below / under each layer is given with reference to the drawings. In addition, the thickness or size of each layer (film), area, pattern, or structure in the drawings may be varied for clarity and convenience of description and is not necessarily indicative of actual size.

[0039] The terms used in the present application are provided only to described specific embodiments, and do not limit the present disclosure. Singular forms are intended to include plurality of forms as well, unless the context clearly indicates otherwise. In the present application, it should be understood that the terms "includes," "has," etc. specify the presence of stated features, numbers, steps, operations, elements, components, or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof.

[0040] All terms, including technical and scientific terms, have the same meanings as those commonly understood by one of ordinary skill in the art to which this disclosure pertains, unless defined otherwise. Commonly used terms, such as those defined in typical dictionaries, should be interpreted as being consistent with the contextual meaning of the relevant art, and are not to be construed in an ideal or overly formal sense unless expressly defined to the contrary.

[0041] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings, wherein identical or corresponding components are denoted by the same reference symbols regardless of drawing designation, and duplicative descriptions thereof will be omitted.

[0042] In addition, some embodiments are described using a Cartesian coordinate system (X-axis, Y-axis, Z-axis), and in the Cartesian coordinate system, the X-axis, Y-axis, and Z-axis shown in each figure are orthogonal to each other, but the present disclosure is not limited thereto. The X-axis, Y-axis, and Z-axis may intersect each other. Hereinafter, for convenience of description, the Z-axis direction is referred to as a vertical direction, and each of the X-axis direction and the Y-axis direction is referred to as a horizontal direction. Furthermore, the X-axis direction is referred to as a first direction, the Y-axis direction is referred to as a second direction, and the Z-axis direction is referred to as a third direction.

[0043] Hereinafter, a magnetic element 100A according to an embodiment will be described in detail with reference to the accompanying drawings.

[0044] FIG. 1 is an assembled perspective view of a magnetic element 100A according to an embodiment, FIG. 2 is an exploded perspective view of the magnetic element 100A shown in FIG. 1, FIG. 3 is a perspective view of the magnetic element 100A shown in FIG. 1 with a first core 112A removed, FIG. 4 is a perspective view of the magnetic element 100A shown in FIG. 1 with a core unit 110A removed, FIGs. 5A to 5G are, respectively, an upper perspective view, a lower perspective view, a front view, a rear view, a plan view, a bottom view, and a side view of a bobbin unit 120A shown in FIG. 2, and FIG. 6 is a sectional view taken along line I-I' of FIG. 1.

[0045] The magnetic element 100A according to the embodiment may include a core unit 110A, a bobbin unit 120A, and a coil unit 130A.

[0046] The core unit 110A may have the nature of a magnetic circuit and serve as a path for magnetic flux. The core unit 110A may include a first core 112A and a second core 114A. The first core 112A and the second core 114A may be disposed opposite each other in a first direction.

[0047] The first core 112A may include a first body portion B11, a first outer leg portion OL11, a second outer leg portion OL12, and a central leg portion CL1, and the second core 114A may include a first body portion B12, a first outer leg portion OL21, a second outer leg portion OL22, and a central leg portion CL2.

[0048] Each of the first outer leg portions OL11 and OL21 may protrude from one end of a corresponding one of the first body portions B11 and B12, which may be flat, in the first direction, and may extend in a second direction intersecting the first direction.

[0049] Each of the second outer leg portions OL12 and OL22 may protrude from the other end of a corresponding one of the first body portions B11 and B12 in the first direction, and may extend in the second direction.

[0050] Each of the central leg portions CL1 and CL2 may protrude in the first direction between a corresponding one of the first outer leg portions OL11 and OL21 and a corresponding one of the second outer leg portions OL12 and OL22, and may extend in the second direction.

[0051] The first core 112A may be disposed on the second core 114A. The first and second cores 112A and 114A may have symmetrical shapes or asymmetrical shapes. However, for the sake of convenience in the following description, the first and second cores are assumed to have symmetrical shapes.

[0052] When the first core 112A and the second core 114A are vertically coupled to each other, the first and second outer leg portions OL11 and OL12 and the central leg portion CL1 of the first core 112A are opposite the first and second outer leg portions OL21 and OL22 and the central leg portion CL2 of the second core 114A, respectively. At this time, a gap of a predetermined distance may be formed between at least some of the opposing outer leg pairs or central leg pairs. In the case of FIG. 6, the predetermined distance is illustrated as '0', but the embodiment is not limited thereto. For example, the predetermined distance of the gap may be 10 µm to 100 µm, but the embodiment is not necessarily limited thereto. For example, the predetermined distance of the gap may be 100 µm and may be set variously depending on the embodiment.

[0053] In addition, the core unit 110A (112A and 114A) may include a magnetic material, such as iron or ferrite, but the embodiment is not necessarily limited thereto.

[0054] Meanwhile, at least a part of the bobbin unit 120A may be disposed in the core unit 110A.

[0055] The coil unit 130A may include an upper coil 132 and a lower coil 134 disposed, i.e., wound, on the bobbin unit 120A. Referring to FIG. 6, at least a part of the upper coil 132 may be disposed between each of the first and second outer leg portions OL11 and OL12 and the central leg portion CL1 of the first core 112A, and at least a part of the lower coil 134 may be disposed between each of the first and second outer leg portions OL21 and OL22 and the central leg portion CL2 of the second core 114A.

[0056] In the case of FIG. 6, each of the upper coil 132 and the lower coil 134 is shown as contacting a second body portion B2 of the bobbin unit 120A described later, but the embodiment is not limited thereto. That is, according to another embodiment, each of the upper coil 132 and the lower coil 134 may be disposed spaced apart from the second body portion B2 in a third direction. That is, each of the upper coil 132 and the lower coil 134 may be disposed closer to the outer leg portions OL11, OL12, OL21, and OL22 than to the central leg portions CL1 and CL2.

[0057] According to the embodiment, the upper coil 132 and the lower coil 134 may be disposed spaced apart from each other in the first direction. That is, as shown in FIG. 6, the upper coil 132 and the lower coil 134 may be disposed spaced apart from each other with a space SP therebetween. If the distance by which the upper coil 132 and the lower coil 134 are spaced apart from each other in the first direction, i.e., the width X5 of the space SP in the first direction, is less than 1 mm, short circuit may occur between the upper coil 132 and the lower coil 134. If the distance is greater than 2 mm, the area available for winding may decrease, making it difficult to achieve desired power capacity. Therefore, the width X5 may be 1 mm to 2 mm, but the embodiment is not limited thereto.

[0058] According to an embodiment, the upper coil 132 may be a primary coil, and the lower coil 134 may be a secondary coil. According to another embodiment, the lower coil 134 may be a primary coil, and the upper coil 132 may be a secondary coil.

[0059] Each of the upper coil 132 and the lower coil 134 may include a plurality of conductive wires wound so as to form a plurality of turns around a first through-hole TH1.

[0060] Each of the upper coil 132 and the lower coil 134 may be a plurality of conductive wires (or a plurality of windings) formed by winding a rigid conductive metal, such as copper conductive wire, in a spiral form or a planar spiral form a plurality of times, but the embodiment is not necessarily limited thereto. For example, enameled wire (USTC wire) wrapped with fiber yarn, Litz wire, triple insulated wire (TIW), etc. may be applied to at least one of the upper coil 132 or the lower coil 134.

[0061] Hereinafter, the configuration of the bobbin unit 120A will be described with reference to the accompanying drawings.

[0062] The bobbin unit 120A may include a second body portion B2, a first upper protrusion UP1, and a first lower protrusion DP1.

[0063] The upper coil 132 and the lower coil 134 may be disposed on the second body portion B2 so as to be spaced apart from each other in the first direction.

[0064] As shown in FIG. 5C, the first upper protrusion UP1 may protrude from upper ends UE1 and UE2 of the second body portion B2 not only in a second direction but also in the third direction intersecting the first and second directions.

[0065] The first upper protrusion UP1 may include 1-1 and 1-2 upper protrusions UP11 and UP12. The 1-1 upper protrusion UP11 may protrude from the upper end UE1 of the second body portion B2 in the second and third directions, and may be disposed between the first outer leg portion OL11 and the central leg portion CL1 of the first core 112A. The 1-2 upper protrusion UP12 may protrude from the upper end UE2 of the second body portion B2 in the second and third directions, and may be disposed between the second outer leg portion OL12 and the central leg portion CL1 of the first core 112A. The 1-2 upper protrusion UP12 may be located on the opposite side of the 1-1 upper protrusion UP11 in the third direction.

[0066] The first upper protrusion UP1 disposed in this manner may perform the role of not only supporting the first core 112A but also preventing upward disengagement of the upper coil 132 wound on a fifth body portion B5.

[0067] The first lower protrusion DP1 may protrude from a lower end of the second body portion B2 in the third direction. The first lower protrusion DP1 may include 1-1 and 1-2 lower protrusions DP11 and DP12.

[0068] The 1-1 lower protrusion DP11 may be disposed between the first outer leg portion OL21 and the central leg portion CL2 of the second core 114A, and the 1-2 lower protrusion DP12 may be disposed between the second outer leg portion OL22 and the central leg portion CL2 of the second core 114A. The 1-2 lower protrusion DP12 may be disposed on the opposite side of the 1-1 lower protrusion DP11 in the third direction.

[0069] The first lower protrusion DP1 disposed in this manner may perform the role of not only supporting the lower coil 134 but also preventing downward disengagement of the lower coil 134 wound on the fifth body portion B5.

[0070] According to the embodiment, the first upper protrusion UP1 and the first lower protrusion DP1 may overlap in the first direction to form a space in which the upper coil 132 and the lower coil 134 are received.

[0071] In addition, the bobbin unit 120A may further include a coil support portion 122. The coil support portion 122 protrudes horizontally from the second body portion B2 between the first upper protrusion UP1 and the first lower protrusion DP1 to support the upper coil 132.

[0072] According to an embodiment, as shown, the coil support portion 122 may be disposed at a corner of the second body portion B2.

[0073] According to another embodiment, referring to FIG. 5C, the coil support portion 122 may be disposed in an area 122K immediately above a 2-2 through-hole TH22 instead of the corner of the second body portion B2.

[0074] In addition, although the coil support portion 122 may be disposed above the 2-2 through-hole TH22, as shown, the coil support portion may be disposed so as to horizontally overlap the 2-2 through-hole TH22 or disposed under the 2-2 through-hole TH22. For example, unlike what is shown in FIG. 5D, the coil support portion 122 and the 2-2 through-hole TH22 may be disposed on an imaginary horizontal line HL. However, the embodiment is not limited to a specific position and form in which the coil support portion 122 is disposed as long as it is possible to support the upper coil 132.

[0075] In addition, the bobbin unit 120A may further include a first through-hole TH1. The first through-hole TH1 may be formed through the second body portion B2 in the first direction, and the central leg portions CL1 and CL2 of the first core 112A and the second core 114A may be inserted into and disposed in the first through-hole TH1.

[0076] Referring to FIG. 5G, the first through-hole TH1 has a first length X1 in the first direction, and referring to FIG. 2, the central leg portion CL1 of the first core 112A may have a second length X2 in the first direction, and the central leg portion CL2 of the second core 114A may have a third length X3 in the first direction.

[0077] According to an embodiment, as shown in FIG. 6, the sum of the second length X2 and the third length X3 may be equal to the first length X1.

[0078] According to another embodiment, the sum of the second length X2 and the third length X3 may be less than the first length X1.

[0079] In addition, the bobbin unit 120A may further include a second through-hole TH2 (TH21 and TH22). The second through-hole TH2 may be formed through the second body portion B2 in the second or third direction. For example, the second through-hole TH2 may include a 2-1 through-hole TH21 formed through the second body portion B2 in the third direction and a 2-2 through-hole TH22 formed through the second body portion B2 in the second direction.

[0080] According to the embodiment, the second through-hole TH2 may overlap the space SP between the upper coil 132 and the lower coil 134 shown in FIG. 6 in the second or third direction. To this end, the position of the coil support portion 122 may be determined.

[0081] According to the embodiment, the length X4 of the second through-hole TH2 in the first direction may be greater than the length X5 of the space SP in the first direction. Therefore, at least one of the upper coil 132 or the lower coil 134 may overlap the second through-hole TH2 in the second or third direction. For example, the length X4 may be 1 mm to 5 mm, but the embodiment is not limited thereto.

[0082] In addition, referring to FIG. 5G, the second body portion B2 may include an upper area UA and a lower area LA. The upper area UA may be defined as the area located between the first upper protrusion UP1 (UP11 and UP12) and the second through-hole TH2, and the lower area LA may be defined as the area located between the second through-hole TH2 and the first lower protrusion DP11 and DP12.

[0083] The upper coil 132 may overlap the upper area UA in the third direction, and the lower coil 134 may overlap the lower area LA in the third direction.

[0084] Meanwhile, the second body portion B2 may further include first to fourth side portions S1 to S4.

[0085] The first and second side portions S1 and S2 may be opposite each other in the third direction with the first through-hole TH1 interposed therebetween, and the third and fourth side portions S3 and S4 may be opposite each other in the second direction with the first through-hole TH1 interposed therebetween and may be located between the first side portion S1 and the second side portion S2.

[0086] The second through-hole TH2 may include a 2-1 through-hole TH21 disposed in each of the first and second side portions S1 and S2 and formed through the second body portion B2 in the third direction and a 2-2 through-hole TH22 disposed in each of the third and fourth side portions S3 and S4 and formed through the second body portion B2 in the second direction.

[0087] The 2-1 through-holes TH21 and the 2-2 through-holes TH22 may have the same size or number, but the embodiment is not limited to a specific size or number of the second through-holes TH2 (TH21 and TH22).

[0088] As shown, in the horizontal direction, each of the first and second side portions S1 and S2 has a larger length than each of the third and fourth side portions S3 and S4. Therefore, when the sizes of the 2-1 and 2-2 through-holes TH21 and TH22 are the same, the number of 2-1 through-holes TH21 disposed in each of the first and second side portions S1 and S2 may be greater than the number of 2-2 through-holes TH22 disposed in each of third and fourth side portions S3 and S4. For example, as shown, the number of 2-1 through-holes TH21 may be four and the number of 2-2 through-holes TH22 may be two, but the embodiment is not limited thereto.

[0089] According to another embodiment, the number of 2-1 through-holes TH21 and the number of 2-2 through-holes TH22 may be the same, and the size of the 2-1 through-hole TH21 may be greater than the size of the 2-2 through-hole TH22.

[0090] In addition, the bobbin unit 120A may include first and second lower central protrusions LCP1 and LCP2, a first lower peripheral protrusion LPP11 and LPP12, and a second lower peripheral protrusion LPP21 and LPP22.

[0091] The first lower central protrusion LCP1 protrudes from a lower end of the third side portion S3 of the second body portion B2 in the first and second directions, and the second lower central protrusion LCP2 protrudes from a lower end of the fourth side portion S4 of the second body portion B2 in the first and second directions. The first and second lower central protrusions LCP1 and LCP2 serve to support the lower coil 134, as shown in FIGs. 1, 3, and 4.

[0092] The first lower peripheral protrusion LPP11 and LPP12 protrudes from one end of the first lower protrusion DP11 and DP12 in the first and second directions and is disposed on the periphery of the first lower central protrusion LCP1. That is, the 1-1 lower peripheral protrusion LPP11 protrudes from one end of the 1-1 lower protrusion DP11 in the first and second directions and is disposed on one side of the periphery of the first lower central protrusion LCP1, and the 1-2 lower peripheral protrusions LPP12 protrudes from one end of the 1-2 lower protrusions DP12 in the first and second directions and is disposed on the other side of the periphery of the first lower central protrusion LCP1.

[0093] The second lower peripheral protrusion LPP21 and LPP22 protrudes from the other end of the first lower protrusion DP11 and DP12 in the first and second directions and is disposed on the periphery of the second lower central protrusion LCP2. That is, the 2-1 lower peripheral protrusion LPP21 protrudes from the other end of the 1-1 lower protrusion DP11 in the first and second directions and is disposed on one side of the periphery of the second lower central protrusion LCP2, and the 2-2 lower peripheral protrusion LPP22 protrudes from the other end of the 1-2 lower protrusion DP12 in the first and second directions and is disposed on the other side of the periphery of the second lower central protrusion LCP2.

[0094] Referring to FIGs. 5C and 5D, a bottom surface BSC1 of the first lower central protrusion LCP1, a bottom surface BSC2 of the second lower central protrusion LCP2, a bottom surface BSP11 of the 1-1 lower peripheral protrusion LPP11, a bottom surface BSP12 of the 1-2 lower peripheral protrusion LPP12, a bottom surface BSP21 of the 2-1 lower peripheral protrusion LPP21, a bottom surface BSP22 of the 2-2 lower peripheral protrusion LPP22, and a bottom surface 114BS of the first body portion 114A of the second core 114A may be disposed on the same horizontal plane.

[0095] In addition, the thickness T1 of each of the first lower central protrusion LCP1 and the first lower peripheral protrusion LPP11 and LPP12 in the first direction, the thickness T2 of each of the second lower central protrusion LCP2 and the second lower peripheral protrusion LPP21 and LPP22 in the first direction, and the thickness T3 of the first body portion B12 of the second core 114A in the first direction may be the same.

[0096] Therefore, the first body portion B12 of the second core 114A may be received in a first space between the first lower central protrusion LCP1 and the second lower central protrusion LCP2 opposite each other in the second direction and a second space between the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22 opposite each other in the second direction.

[0097] In addition, according to the embodiment, each of the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22 has a step. In this case, the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22 may respectively include stepped portions STP1 to STP4, each of which is recessed in the first direction and has a third through-hole TH3.

[0098] Although not shown, the magnetic element 100A according to the embodiment may be connected to a printed circuit board (PCCB). In this case, the third through-hole TH3 of the magnetic element 100A may be a part into which a screw (not shown) that fastens the PCB and the magnetic element 100A to each other is fitted. In this case, the first and second lower central protrusions LCP1 and LCP2 may serve to prevent bending of the magnetic element 100A when the screw is fastened. To this end, the first and second lower central protrusions LCP1 and LCP2, the first lower peripheral protrusion LPP11 and LPP12, and the second lower peripheral protrusion LPP21 and LPP22 may be formed integrally.

[0099] According to the embodiment, as shown in FIGs. 5C and 5D, the width of a lower side of the bobbin unit 120A in the third direction may be greater than the width of an upper side of the bobbin unit 120A in the third direction.

[0100] Referring to FIGs. 3 and 4, first and second wires W1 and W2 drawn out respectively from both ends of the lower coil 134 are supported by the second lower peripheral protrusion LPP21 and LPP22. On the other hand, third and fourth wires W3 and W4 drawn out respectively from both ends of the upper coil 132 overlap the first lower peripheral protrusion LPP11 and LPP12 in the first direction but are not supported by the first lower peripheral protrusion LPP11 and LPP12.

[0101] In this case, each of a plurality of terminal pins (or connection ends) TM1 to TM4 may be disposed at a distal end of a corresponding one of the first to fourth wires W1 to W4. The plurality of terminal pins may be connected to a power supply unit and parts.

[0102] In order for the second lower peripheral protrusion LPP21 and LPP22 to stably support the first and second wires W1 and W2, the second lower peripheral protrusion LPP21 and LPP22 may have a larger surface area than the first lower peripheral protrusion LPP11 and LPP12. That is, referring to FIG. 5F, the surface area SA11 of the 1-1 lower peripheral protrusion LPP11, the surface area SA12 of the 1-2 lower peripheral protrusion LPP12, the surface area SA21 of the 2-1 lower peripheral protrusion LPP21, and the surface area SA22 of the 2-2 lower peripheral protrusion LPP22 are given by Equation 1 below. SA 11 = Y 1 × Z 11 SA 12 = Y 1 × Z 12 SA 21 = Y 2 × Z 21 SA 22 = Y 2 × Z 21

[0103] Here, Y1 indicates the length of the first lower peripheral protrusion LPP11 and LPP12 in the second direction, Y2 indicates the length of the second lower peripheral protrusion LPP21 and LPP22 in the second direction, Z11 indicates the length of the 1-1 lower peripheral protrusion LPP11 in the third direction, Z12 indicates the length of the 1-2 lower peripheral protrusion LPP12 in the third direction, Z21 indicates the length of the 2-1 lower peripheral protrusion LPP21 in the third direction, and Z22 indicates the length of the 2-2 lower peripheral protrusion LPP22 in the third direction.

[0104] These surface areas SA11, SA12, SA21, and SA22 may have the relationship shown in Equation 2 below. SA 11 < SA 21 SA 11 < SA 22 SA 12 < SA 21 SA 12 < SA 22

[0105] Hereinafter, a magnetic element 100B according to another embodiment will be described with reference to the accompanying drawings.

[0106] FIG. 7 is an assembled perspective view of a magnetic element 100B according to another embodiment, FIG. 8 is an exploded perspective view of the magnetic element 100B shown in FIG. 7, FIG. 9 is a perspective view of the magnetic element 100B shown in FIG. 7 with a first upper core segment 112B1 removed, FIG. 10 is a perspective view of the magnetic element 100B shown in FIG. 7 with a first core 112B removed, and FIG. 11 is a perspective view of the magnetic element 100B shown in FIG. 7 with the first core 112B and a second lower core segment 114B1 removed.

[0107] The magnetic element 100B according to the other embodiment has a configuration in which at least one of first and second cores 112B and 114B is divided in the second direction, unlike the magnetic element 100A according to the embodiment. Consequently, except that the shape of a core unit 110B differs from that of the core unit 110A, the description of the magnetic element 100A according to the embodiment may apply to the magnetic element 100B according to the other embodiment shown in FIGs. 7 to 11. Therefore, identical parts are denoted by the same reference numerals, and duplicative descriptions thereof will be omitted.

[0108] According to the other embodiment, the magnetic element 100B may include a core unit 110B, a bobbin unit 120B, and a coil unit 130A.

[0109] The core unit 110B may include first and second cores 112B and 114B.

[0110] The first core 112B may include a plurality of upper core segments divided in the second direction, and the second core 114B may include a plurality of lower core segments divided in the second direction and disposed opposite the plurality of upper core segments in the first direction.

[0111] For example, as shown, each of the first core 112B and the second core 114B may be divided into two segments, but the embodiment is not limited thereto, and each of the first core and the second core may be divided into three or more segments. In the shown case, the first core 112B may be divided into first and second upper core segments 112B1 and 112B2, and the second core 114B may be divided into first and second lower core segments 114B1 and 114B2.

[0112] Hereinafter, each of the first core 112B and the second core 114B will be described as being divided into two segments, but the following description may also apply to the case in which each of the first core 112B and the second core 114B are divided into three or more segments as described later.

[0113] The first core 112B may include first and second upper core segments 112B1 and 112B2. Each of the first and second upper core segments 112B1 and 112B2 may include a first body portion B11, a first outer leg portion OL111, a second outer leg portion OL112, and a central leg portion CL11.

[0114] The second core 114B may include first and second lower core segments 114B1 and 114B2. Each of the first and second lower core segments 114B1 and 114B2 may include a first body portion B12, a first outer leg portion OL221, a second outer leg portion OL222, and a central leg portion CL22.

[0115] Each of the first outer leg portions OL111 and OL221 may protrude from one end of a corresponding one of the first body portions B11 and B12 in the first direction, and may extend in the second direction. Each of the second outer leg portions OL112 and OL222 may protrude from the other end of a corresponding one of the first body portions B11 and B12 in the first direction, and may extend in the second direction. Each of the central leg portions CL11 and CL22 may protrude in the first direction between a corresponding one of the first outer leg portions OL111 and OL221 and a corresponding one of the second outer leg portions OL112 and OL222, and may extend in the second direction.

[0116] Meanwhile, the bobbin unit 120B may include a second body portion B2, a first upper protrusion UP1, and a first lower protrusion DP1.

[0117] The coil unit 130A may be disposed on the second body portion B2, and may include an upper coil 132 and a lower coil 134 wound on the second body portion B2 so as to be spaced apart from each other in the first direction. The upper coil 132 is one of a primary coil and a secondary coil, and the lower coil 134 may be the other of the primary coil and the secondary coil.

[0118] Alternatively, the primary coil and the secondary coil may be disposed on the bobbin unit 120B without being spaced apart in the first direction, unlike the coil unit 130A of the magnetic element 100A according to the embodiment. The magnetic element 100B according to the other embodiment is not limited to a specific configuration in which the primary coil and secondary coil are disposed.

[0119] The first upper protrusion UP1 may include a 1-1 upper protrusion UP11 and a 1-2 upper protrusion UP12.

[0120] The 1-1 upper protrusion UP11 may be disposed between the first outer leg portion OL111 and the central leg portion CL11 of each of the first and second upper core segments 112B1 and 112B2, and the 1-2 upper protrusion UP12 may be disposed between the second outer leg portion OL112 and the central leg portion CL11 of each of the first and second upper core segments 112B1 and 112B2 and located on the opposite side of the 1-1 upper protrusion UP11 in the third direction. Consequently, the 1-1 and 1-2 upper protrusions UP11 and UP12 serve to support the plurality of upper core segments 112B1 and 112B2.

[0121] The first lower protrusion DP1 may include 1-1 and 1-2 lower protrusions DP11 and DP12. The 1-1 lower protrusion DP11 may be disposed between the first outer leg portion OL221 and the central leg portion CL22 of each of the first and second lower core segments 114B1 and 114B2, and the 1-2 lower protrusion DP12 may be disposed between the second outer leg portion OL222 and the central leg portion CL22 of each of the first and second lower core segments 114B1 and 114B2 and located on the opposite side of the 1-1 lower protrusion DP11 in the third direction.

[0122] In addition, the central leg portion CL11 of each of the first and second upper core segments 112B1 and 112B2 and the central leg portion CL22 of each of the first and second lower core segments 114B1 and 114B2 may be inserted into and disposed in the first through-hole TH1 of the second body portion B2 shown in FIGs. 5A to 5G. The description of the sizes of the central leg portions CL1 and CL2 and the first through-hole TH1 may also apply to the central leg portions CL11 and CL22, and duplicative descriptions thereof will be omitted.

[0123] In addition, duplicative descriptions of parts of the bobbin unit 120B of the magnetic element 100B identical to those of the bobbin unit 120A of the magnetic element 100A according to the embodiment will be omitted, and only different parts will be described.

[0124] In the magnetic element 100B according to the other embodiment, each of the first and second cores 112A and 114B may be divided in the second direction and each of the plurality of divided upper core segments and the plurality of divided lower core segments is spaced apart from each other by a uniform distance, unlike the magnetic element 100A according to the embodiment.

[0125] To this end, according to the embodiment, the magnetic element 100B may further include first and second adhesive portions AD1, AD2, AD3, and AD4.

[0126] The first and second adhesive portions AD1 and AD2 adhere a bottom surface BS1 of the first body portion B11 of each of the first and second upper core segments 112A and 112B to an upper surface TSF of the first upper protrusion UP1 to maintain a uniform distance between the first and second upper core segments 112B1 and 112B2.

[0127] The third and fourth adhesive portions AD3 and AD4 adhere an upper surface BS2 of the first body portion B12 of each of the first and second lower core segments 114A and 114B to a lower surface ST3 of the first lower protrusion DP1 shown in FIG. 5F to maintain a uniform distance between the first and second lower core segments 114B1 and 114B2.

[0128] According to another embodiment, since each of the first and second cores 112A and 114B of the magnetic element 100B is divided in the second direction, the magnetic element 100B may include first to fourth stoppers (or spacers) ST1, ST2, ST3, and ST4 in order to maintain a uniform distance between the plurality of divided upper core segments and between the plurality of divided lower core segments.

[0129] The first and second stoppers ST1 and ST2 are disposed on an upper surface of the first upper protrusion UP1 (UP11 and UP12) between the first body portions B11 of the first and second upper core segments 112B1 and 112B2 to maintain a uniform distance between the first and second upper core segments 112B1 and 112B2.

[0130] The second and fourth stoppers ST3 and ST4 are disposed on a lower surface of the first lower protrusion DP1 (DP11 and DP12) between the first body portions B12 of the first and second lower core segments 114B1 and 114B2 to maintain a uniform distance between the first and second lower core segments 114B1 and 114B2.

[0131] According to the embodiment, as shown, the magnetic element 100B may include both the first to second adhesive portions AD1 to AD4 and the first to second stoppers ST1 to ST4, may include only the first to second adhesive portions AD1 to AD4, or may include only the first to second stoppers ST1 to ST4.

[0132] According to the embodiment, the plurality of upper core segments 112B1 and 112B2 may be disposed spaced apart from each other by a first gap GS1 in the second direction, and the plurality of lower core segments 114B1 and 114B2 may be disposed spaced apart from each other by a second gap GS2 in the second direction.

[0133] According to the embodiment, the widths of the first gap GS1 and the second gap GS2 in the horizontal direction may be the same. For example, if the width of each of the first gap GS1 and the second gap GS2 in the second direction is less than 0.1 mm, an inlet through which air flows from the outside into the magnetic element 100B becomes narrower, making it difficult for the outside air to remove the heat in the magnetic element 100B. If the width is greater than 1.0 mm, the first gap GS1 and the second gap GS2 may generate fringing flux, increasing magnetic flux and potentially affecting heat generation. Therefore, the width of each of the first gap GS1 and the second gap GS2 in the second direction may be 0.1 mm to 1.0 mm, but the embodiment is not limited thereto.

[0134] In the magnetic element 100A according to the embodiment, the primary coil and the secondary coil are spaced apart from each other in the first direction to form an air flow path between the primary coil and the secondary coil, enabling effective removal of the heat generated by the coils, whereby it is possible to improve heat dissipation performance, i.e., cooling performance.

[0135] In addition, the plurality of second through-holes TH2 and the space SP between the primary coil and the secondary coil are disposed so as to overlap each other in the third direction, whereby air introduced through the second through-holes TH2 easily flows into the space SP. Consequently, a fan cooling path is formed, thereby further improving the cooling performance.

[0136] In addition, since the first body portion B12 of the second core 114A or 114B is received in a first space between the first lower central protrusion LCP1 and the second lower central protrusion LCP2 and a second space between the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22, a separate space for receiving the second core 114A or 114B is not required, whereby the size of the magnetic element 100A or 100B may be reduced, enabling miniaturization.

[0137] Furthermore, if each of the first and second cores 112A and 114A is not divided, the amount of air that flows into the magnetic element 100A may not be sufficient. However, in the magnetic element 100B according to the other embodiment, since the first and second cores 112B and 114B are divided in the second direction and disposed spaced apart from each other with the gaps GS1 and GS2 therebetween, sufficient air may flow from the outside into the magnetic element 100B through the gaps GS1 and GS2 to remove heat, thereby further improving the cooling performance. The cooling performance advantage becomes more pronounced as the magnetic element 100B increases in size.

[0138] Hereinafter, a magnetic element 100C according to another embodiment will be described with reference to the accompanying drawings.

[0139] FIG. 12 is an assembled perspective view of a magnetic element 100C according to a yet another embodiment, FIG. 13 is an exploded perspective view of the magnetic element 100C shown in FIG. 12, FIG. 14 is a perspective view of the magnetic element 100C shown in FIG. 12 with first and second upper core segments 112C1 and 112C2 removed, FIG. 15 is a perspective view of the magnetic element 100C shown in FIG. 12 with a first core 112C removed, FIG. 16 is a perspective view of the magnetic element 112C shown in FIG. 12 with the first core 112C and a first lower core segment 114C1 removed, and FIGs. 17A to 17C are, respectively, an upper perspective view, a plan view, and a front view of a bobbin 120C shown in FIG. 13.

[0140] FIG. 6 corresponds to a sectional view taken along line II-II' of FIG. 12.

[0141] The magnetic element 100C according to the yet another embodiment has a configuration in which at least one of first and second cores 112C and 114C is divided in the second direction, unlike the magnetic element 100A according to the embodiment.

[0142] In addition, while the magnetic element 100B according to the other embodiment has a configuration in which each of the first and second cores 112B and 114B is divided into two segments in the second direction, the magnetic element 100C according to the yet another embodiment has a configuration in which each of the first and second cores 112C and 114C is divided into three segments in the second direction.

[0143] In addition, spacers USTL, USTR, LSTR, and LSTL disposed on the bobbin 120C of the magnetic element 100C according to the yet another embodiment differ in form and position from the spacers ST1, ST2, ST3, and ST4 of the magnetic element 100B according to the other embodiment.

[0144] In addition, the magnetic element 100C according to the yet another embodiment does not include a coil support portion 122, unlike the magnetic elements 100B and 100C according to the embodiment and the other embodiment.

[0145] In addition, a second upper protrusion UP2 of the magnetic element 100C according to the yet another embodiment has a different shape from the first upper protrusion UP1 of each of the magnetic elements 100A and 100B according to the embodiment and the other embodiment.

[0146] As described above, the magnetic element 100C according to the yet another embodiment has several different features from the magnetic elements 100A and 100B according to the embodiment and the other embodiment. Therefore, parts of the magnetic element 100C identical to parts of each of the magnetic elements 100A and 100B according to the embodiment and the other embodiment are denoted by the same reference numerals, duplicative descriptions thereof will be omitted, and only different parts will be described. That is, the description of the magnetic elements 100A and 100B according to the aforementioned embodiments may apply to the undescribed parts of the magnetic element 100C.

[0147] According to the yet another embodiment, the magnetic element 100C may be constituted by a core unit 110C, a bobbin unit 120C, and a coil unit 130B.

[0148] The core unit 110C may include first and second cores 112C and 114C.

[0149] The first core 112C may include a plurality of upper core segments divided in the second direction, and the second core 114C may include a plurality of lower core segments divided in the second direction and disposed opposite the plurality of upper core segments in the first direction.

[0150] For example, as shown, each of the first core 112C and the second core 114C may be divided into three segments, but the embodiment is not limited thereto, and each of the first core and the second core may be divided into four or more segments. In the shown case, the first core 112C may be divided into first to third upper core segments 112C1, 112C2, and 112C3, and the second core 114C may be divided into first to third lower core segments 114C1, 114C2, and 114C3.

[0151] Hereinafter, each of the first core 112C and the second core 114C will be described as being divided into three segments, but the following description may also apply to the case in which each of the first core 112CB and the second core 114C is divided into four or more segments.

[0152] Each of the first to third upper core segments 112C1, 112C2, and 112C3 may include a third body portion B3, a first outer leg portion OL311, a second outer leg portion OL312, and a central leg portion CL31.

[0153] Each of the first to third lower core segments 114C1, 114C2, and 114C3 may include a fourth body portion B4, a first outer leg portion OL321, a second outer leg portion OL322, and a central leg portion CL32.

[0154] The first outer leg portion OL311 may protrude from one end of the third body portion B3 in the first direction and extend in the second direction, and the first outer leg portion OL321 may protrude from one end of the fourth body portion B4 in the first direction and extend in the second direction.

[0155] The second outer leg portion OL312 may protrude from the other end of the third body portion B3 in the first direction and extend in the second direction, and the second outer leg portion OL322 may protrude from the other end of the fourth body portion B4 in the first direction and extend in the second direction. Each of the central leg portions CL31 and CL32 may protrude in the first direction between a corresponding one of the first outer leg portions OL311 and OL321 and a corresponding one of the second outer leg portions OL312 and OL322, and may extend in the second direction.

[0156] Meanwhile, the bobbin unit 120C may include a fifth body portion B2, a second upper protrusion UP2, and a first lower protrusion DP1.

[0157] Except for the shape and position of 2-1 and 2-2 through-holes TH21 and TH22 included in the fifth body portion B5 differing from those of the second body portion B2 according to the aforementioned embodiment, the fifth body portion B5 is identical to the second body portion B2, and therefore duplicative descriptions thereof will be omitted. The shape and position of the 2-1 and 2-2 through-holes TH21 and TH22 will be described later. In addition, the first lower protrusion DP1 is identical to the first lower protrusion DP1 of each of the aforementioned magnetic elements 100A and 100B, and therefore the same reference numerals are used and duplicative descriptions thereof will be omitted.

[0158] Unlike the aforementioned embodiments 100A and 100B, the bobbin unit 120C may not include a coil support portion 122. To this end, an upper coil 132 may be securely wound on the bobbin unit 120C so as not to descend in the direction of gravity.

[0159] The second upper protrusion UP2 may protrude from an upper end of the fifth body portion B5 in the second and third directions. Referring to FIG. 17B, the second upper protrusion UP2 may include a 2-1 upper protrusion UP21 and a 2-2 upper protrusion UP22. Each of the 2-1 upper protrusion UP21 and the 2-2 upper protrusion UP22 may include first and second outer upper protrusions OUP1 and OUP2 and an inner upper protrusion IUP.

[0160] In each of the 2-1 upper protrusions UP21 and the 2-2 upper protrusions UP22, the first and second outer upper protrusions OUP1 and OUP2 correspond to the parts disposed outside the core unit 110C, while the inner upper protrusion IUP corresponds to the part disposed inside the core unit 110C.

[0161] The 2-1 upper protrusion UP21 protrudes from the upper end of the fifth body portion B5 (e.g., UE1 shown in FIG. 17C) in at least one of the second direction or the third direction. The 2-1 upper protrusion UP21 is disposed between the first outer portion OL311 and the central leg portion CL31 of each of the first to third upper core segments 112C1, 112C2, and 112C3.

[0162] The 2-2 upper protrusion UP22 protrudes from the upper end of the fifth body portion B5 (e.g., UE2 shown in FIG. 17C) in at least one of the second direction or the third direction. The 2-2 upper protrusion UP22 is disposed between the second outer leg portion OL312 and the central leg portion CL31 of each of the first and second upper core segments 112C1, 112C2, and 112C3, and may be located on the opposite side of the 2-1 upper protrusion UP21 in the third direction. Consequently, the 2-1 and 2-2 upper protrusions UP21 and UP22 serve to support the plurality of upper core segments 112C1, 112C2, and 112C3.

[0163] Except for different shapes of the first and second outer upper protrusions OUP1 and OUP2 and different placement of the spacers USTR, USTL, LSTR, and LSTL, the 2-1 upper protrusion UP21 and the 2-2 upper protrusions UP22 are identical to the 1-1 upper protrusion UP11 and the 1-2 upper protrusion UP12, respectively. Therefore, duplicative descriptions of identical parts will be omitted, and only different parts will be described in detail.

[0164] For example, if each of the first and second thicknesses TK1 and TK2 of the 2-1 and 2-2 upper protrusions UP21 and UP22 in the first direction is less than 1 mm, the 2-1 and 2-2 upper protrusions may be susceptible to breakage. Therefore, each of the first and second thicknesses TK1 and TK2 may be 1 mm or more, but the embodiment is not limited thereto.

[0165] In addition, the width L2 of the 2-1 upper protrusion UP21 in the third direction and the width L1 of the 2-2 upper protrusion UP22 in the third direction may be the same.

[0166] The first through-hole TH1 of the fifth body portion B5 may have a width L3 in the third direction. That is, the width L3 may correspond to the shortest distance between the 2-1 upper protrusion UP21 and the 2-2 upper protrusion UP22 in the third direction. For example, the width L3 may be greater than the width L1 or L2, but the embodiment is not limited thereto.

[0167] In addition, the width of the 1-1 lower protrusion DP11 in the third direction and the width of the 1-2 lower protrusion DP12 in the third direction may be the same.

[0168] FIG. 18A is a plan view of a right corner of the magnetic element 100C shown in FIG. 12, FIG. 18B is a plan view of a left corner of the magnetic element 100C shown in FIG. 12 with the second outer upper protrusion OUP2 removed, FIG. 18C is a combined plan view of the coil unit 130B and the second core 114C, and FIG. 18D is a plan view of another embodiment of the right corner of the magnetic element 100C shown in FIG. 12. In FIG. 18B, an outer upper protrusion CV4 is shown as a dotted line to aid in understanding the placement thereof relative to the upper coil 132.

[0169] The first and second outer upper protrusions OUP1 and OUP2 protrude from the inner upper protrusion IUP in the second direction intersecting the first direction and are located outside the core unit 110C. The inner upper protrusion IUP protrudes from the fifth body portion B5 in the third direction and is located in the core unit 110C.

[0170] Referring to FIG. 17B, each of the first outer upper protrusion OUP1 (hereinafter referred to as 'CV1') of the 2-1 upper protrusion UP21 and the first outer upper protrusion OUP2 (hereinafter referred to as 'CV2') of the 2-2 upper protrusion UP22 may have a fan-shaped planar configuration with a central angle of 90°.

[0171] In addition, each of the second outer upper protrusion OUP2 (hereinafter referred to as 'CV3') of the 2-1 upper protrusion UP21 and the second outer upper protrusion OUP2 (hereinafter referred to as 'CV4') of the 2-2 upper protrusion UP22 may also have a fan-shaped planar configuration with a central angle of 90°.

[0172] Each of the outer upper protrusions CV1 to CV4 may include first and second portions P1 and P2. For example, referring to FIG. 18B, the first portion P1 of the outer upper protrusion CV4 corresponds to the part overlapping the coil unit 130B in the first direction, and the second portion P2 thereof corresponds to the part extending horizontally from the first portion P1.

[0173] It is desirable for the second portion P2 to protrude as little as possible from the first portion P1. For example, when the coil unit 130B includes a plurality of coils CO1, CO2, CO3, and CO4, the second portion P2 may extend at least as far as half the diameter Φ of the outermost coil CO4 included in the coil unit 130B. If the size d of the second portion P2 is less than half the diameter Φ, the upper coil 132 may escape when winding the coil unit 130B onto the bobbin unit 120C.

[0174] The coil unit 130B may include an upper coil 132 and a lower coil 134 disposed on the bobbin unit 120C. The description of the coil unit 130A shown in FIG. 6 may apply to the coil unit 130B of the magnetic element 100C according to the yet another embodiment, and therefore duplicative descriptions thereof will be omitted. That is, in the magnetic element 100C according to the yet another embodiment, the depiction of the first to fourth wires W1, W2, W3, and W4 described in the embodiments 100A and 100B is omitted; however, wires W1 to W4 may be connected to the coil 130B of the magnetic element 100C, as in the aforementioned embodiments 100A and 100B.

[0175] The outermost coil (e.g., CO4) of the coil unit 130B and the outermost parts of the outer upper protrusions CV1, CV2, CV3, and CV4 have the same planar shape, i.e., a round planar shape.

[0176] Referring to FIG. 18C, the coil unit 130B may include an inner portion CIP disposed in the core unit 110C and outer portions COP1 and COP2 disposed outside the core unit 110C. That is, the part of the coil unit 130B disposed in the core unit 110C is defined as the inner portion CIP, and the part disposed outside the core unit 110C is defined as the outer portions COP1 and COP2.

[0177] Each of the outer portions COP1 and COP2 may include a central portion CCP and peripheral portions CPP1 and CPP2.

[0178] The first and second outer upper protrusions OUP1 and OUP2 are disposed on the outer portions COP1 and COP2, and the inner upper protrusion IUP is disposed on the inner portion CIP.

[0179] According to an embodiment, the central portion CCP corresponds to the part of each of the outer portions COP1 and COP2 having a quadrangular planar shape, and the peripheral portions CPP1 and CPP2 correspond to the parts of each of the outer portions COP1 and COP2 excluding the central portion CCP and may be disposed on the periphery of the central portion CCP.

[0180] According to another embodiment, the central portion CCP corresponds to the part of each of the outer portions COP1 and COP2 overlapping a central leg portion (e.g. CL32 (CL321, CL322, and CL323) shown in FIG. 18C) of the core unit 110C (e.g. the second core 114C shown in FIG. 18C) in the second direction, and the peripheral portions CPP1 and CPP2 may correspond to the parts of each of the outer portions COP1 and COP2 excluding the central portion CCP.

[0181] Each of the peripheral portions CPP1 and CPP2 may have a fan-shaped planar configuration with a central angle of 90° and disposed on the periphery of the central portion CCP. At this time, the outer upper protrusions CV1, CV2, CV3, and CV4 may be disposed on the peripheral portions CPP1 and CPP2.

[0182] Each of the outer upper protrusions CV1, CV2, CV3, and CV4 may include first, second, and third surfaces SP1, SP2, and SP3.

[0183] As shown in FIG. 18A, the first surface SP1 is a surface adjacent to the central portion CCP and may overlap boundaries BD11, BD12, BD21, and BD22 between the central portion CCP and the peripheral portions CPP1 and CPP2 shown in FIG. 18C in the first direction. The second surface SP2 may overlap a boundary BD2 between the inner portion CIP and the peripheral portions CPP1 and CPP2 in the first direction. The third surface SP3 is disposed between the first surface SP1 and the second surface SP2. According to the embodiment, the third surface SP3 has a curved planar shape.

[0184] According to another embodiment, the first surface SP1 of each of the outer upper protrusions CV1, CV2, CV3, and CV4 may be spaced apart from the boundaries BD11, BD12, BD21, and BD22 by a predetermined distance in the third direction toward the outside of the magnetic element 100C. That is, the first surface SP1 may be spaced apart from the central portion CCP by a predetermined distance in the third direction. For example, as shown in FIG. 18D, the outer upper protrusion CV1 may be spaced apart from the boundary BD11 by a first predetermined distance PY1 in a +z axis direction, the outer upper protrusion CV2 may be spaced apart from the boundary BD12 by a second predetermined distance in a -z axis direction, the outer upper protrusion CV3 may be spaced apart from the boundary BD21 by a third predetermined distance in the +z axis direction, and the outer upper protrusion CV4 may be spaced apart from the boundary BD22 by a fourth predetermined distance in the -z axis direction.

[0185] The first and second predetermined distances may be determined such that at least 50% of the outer portion COP1 is not covered by the outer upper protrusions CV1 and CV2 and is exposed on the plane. In addition, the third and fourth predetermined distances may be determined such that at least 50% of the outer portion COP2 is not covered by the outer upper protrusions CV3 and CV4 and is exposed on the plane. Consequently, a large part of the coil unit 130B may be exposed to an air flow path for cooling the magnetic element 100C, thereby improving heat dissipation performance of the magnetic element 100C.

[0186] FIG. 19A is a plan view of a magnetic element 100D according to a further embodiment, and FIG. 19B is an enlarged view of part 'A' of FIG. 19A.

[0187] Except for different planar shapes of outer upper protrusions CV5 to CV8, the magnetic element 100D according to the further embodiment is identical to the magnetic element 100C according to the yet another embodiment. Therefore, identical parts are denoted by the same reference numerals, and duplicative descriptions thereof will be omitted.

[0188] The outer upper protrusions CV5 to CV8 perform the same function as the outer upper protrusions CV1 to CV4, respectively. First and second upper core segments 112C1 and 112C2 are spaced apart from each other by a predetermined distance YG3 in the second direction, and second and third upper core segments 112C2 and 112C3 are spaced apart from each other by a predetermined distance YG4 in the second direction, wherein the distances YG3 and YG4 may be the same or may differ depending on the case.

[0189] The outer upper protrusion CV8 will be described with reference to FIG. 19B; however, the description of the outer upper protrusion CV8 may also apply to the other outer upper protrusions CV5, CV6, and CV7.

[0190] First, the outer upper protrusion CV8 may have a planar shape that does not extend beyond the outermost one CO1 of the plurality of coils 132 (CO1, CO2, CO3, and CO4) in the second direction.

[0191] The outer upper protrusion CV8 may include fourth, fifth, and sixth surfaces SP4, SP5, and SP6.

[0192] The fourth surface SP4 is a part near the central portion CCP of the coil unit 130B, the fifth surface SP5 is a part of the outer upper protrusion CV8 chamfered (or filleted) as the outermost surface in the third direction, and the sixth surface SP6 is a surface between the fourth surface SP4 and the fifth surface SP5 and corresponds to the outermost surface of the outer upper protrusion CV8 in the second direction.

[0193] According to the embodiment, the fifth surface SP5 may be disposed so as to cover at least 50% of the diameter of the outermost coil CO1 and does not protrude farther than the outermost side of the core unit 110C in the third direction (that is, the -z axis direction). In addition, the sixth surface SP6 may be disposed so as not to extend beyond an outer line of the outermost coil CO1 in the second direction to ensure smooth air flow.

[0194] Furthermore, in the same manner as the outer upper protrusion CV4, the fourth surface SP4 of the outer upper protrusion CV8 may also be spaced apart from the boundary BD22 by a predetermined distance PY2 in the third direction. In this case, the predetermined distance PY2 may be determined such that at least 50% of the outer portion COP2 is not covered by the outer upper protrusions CV7 and CV8 and is exposed on the plane.

[0195] Meanwhile, the magnetic element 100C according to the embodiment may include spacers USTR, USTL, LSTR, and LSTL.

[0196] FIGs. 20A and 20B are, respectively, a side view and a front view of the magnetic element 100C shown in FIG. 12.

[0197] Referring to FIGS. 17A, 17B, and 20A, the bobbin unit 100C may further include upper spacers USTR and USTL and lower spacers LSTR and LSTL.

[0198] The upper spacers USTR and USTL protrudes between the plurality of upper core segments 112C1, 112C2, and 112C3 from the inner upper protrusion IUP in the third direction to maintain a uniform distance between the plurality of upper core segments 112C1, 112C2, and 112C3.

[0199] The lower spacers LSTR and LSTL protrude between the plurality of lower core segments 114C1, 114C2, and 114C3 from the first lower protrusion DP1 (DP11 and DP12) in the third direction to maintain a uniform distance between the plurality of lower core segments 114C1, 114C2, and 114C3.

[0200] The number of each of the upper spacers USTR and USTRL is one less than the number of the plurality of upper core segments 112C1, 112C2, and 112C3, and the number of each of the lower spacers LSTR and LSTRL may be one less than the number of the plurality of lower core segments 114C1, 114C2, and 114C3.

[0201] The spacers ST1, ST2, and ST3 of the magnetic element 100B according to the other embodiment described above protrude in the first direction, whereas in the magnetic element 100C according to the yet another embodiment, at least one of the upper spacers USTR and USTL or the lower spacers LSTR and LSTL may protrude in the third direction.

[0202] In addition, the upper spacers USTR and USTL and the lower spacers LSTR and LSTL may be disposed so as to overlap each other in the first direction. Therefore, the gap YG1 by which the upper core segments 112C1, 112C2, and 112C3 are spaced apart from each other by the upper spacers USTR and USTL and the gap YG2 by which the lower core segments 114C1, 114C2, and 114C3 are spaced apart from each other by the lower spacers LSTR and LSTL may communicate with each other, whereby heat generated in the magnetic core 100C may be discharged through the second through-hole TH2 and smoothly vented to the outside via the gaps YG1 and YG2. To this end, the second through-hole TH2 may communicate with the gaps YG1 and YG2.

[0203] According to the embodiment, referring to FIG. 15, the width YW of each of the upper spacers USTR and USTL or the lower spacers LSTR and LSTL in the second direction may be determined so as to satisfy Equation 3 below. N − 1 × YW ≤ THV

[0204] Here, N indicates the number of divided segments of the first core 112C or the second core 114C, YW indicates the width of the upper spacers USTR and USTL or the lower spacers LSTR and LSTL in the second direction, and THV indicates the distance between the plurality of upper core segments 112C1, 112C2, and 112C3 or the plurality of lower core segments 114C1, 114C2, and 114C3 in the second direction for maintaining the critical reduction amount of inductance that the magnetic element 100C must have to preserve the inductance at the maximum value.

[0205] For example, the width of the upper spacers USTR and USTL in the second direction and the width of the lower spacers LSTR and LSTL in the second direction may be the same. Setting THV to 4 mm or more for heat dissipation of the magnetic element 100C may reduce inductance by 15% or more. Therefore, THV may be determined to be 4 mm, but the embodiment is not limited to a specific value for THV.

[0206] Meanwhile, as the second through-hole TH2 is formed in the bobbin 120A of each of the magnetic elements 100A and 100B according to the aforementioned embodiments has a therein, the second through-hole TH2 may also be formed in the bobbin 120C of each of the magnetic element 100C and 100D in the other embodiments. Hereinafter, the description related to the second through-hole TH2 of the magnetic element 100C may also apply to the magnetic elements 100A, 100B, and 100D according to the aforementioned embodiments.

[0207] FIG. 21A is a combined perspective view of the bobbin 120C and the core unit 110C of the magnetic element 100C shown in FIG. 12, and FIG. 21B is a perspective view of the magnetic element 100C shown in FIG. 21A with the first core 112C removed.

[0208] According to another embodiment, the bobbin 120C may further include a second through-hole TH2 formed through the fifth body portion B5 in a direction intersecting the first direction (e.g., at least one of the second direction or the third direction).

[0209] In the same manner as the second body portion B2, the fifth body portion B5 may include first to fourth side portions S1 to S4. Referring to FIG. 17B, the first and second side portions S1 and S2 may be opposite each other in the third direction intersecting the first direction, and the third and fourth side portions S3 and S4 may be opposite each other in the second direction and disposed between the first and second side portions S1 and S2.

[0210] The second through-hole TH2 may include a plurality of second through-holes TH2 formed in at least one of the first to fourth side sections S1 to S4. According to the embodiment, the plurality of second through-holes TH2 may be located on the same horizontal line.

[0211] For example, the second through-hole TH2 may include a 2-1 through-hole TH21 formed in the first and second side portions S1 and S2 of the fifth body portion B5 and a 2-2 through-hole TH22 formed in the third and fourth side portions S3 and S4 of the fifth body portion B5. Second through-holes TH2 of the same shape and size or second through-holes TH2 of different shapes and size may be formed in the first to fourth side portions S1, S2, S3, and S4 of the fifth body portion B5, and the embodiment is not limited to specific shapes and sizes of the second through-holes TH2.

[0212] For example, the 2-1 and 2-2 through-holes TH21 and TH22 may have the same quadrangular shape, as shown, but the sizes thereof may differ.

[0213] Before describing the second through-hole TH2 in detail, the core unit 110C shown in FIG. 12 will be briefly described with reference to the accompanying drawings as follows.

[0214] FIG. 22 is a combined perspective view of the core unit 110C shown in FIG. 13.

[0215] As described above, the central leg portion CL31 of the first core 112C and the central leg portion CL32 of the second core 114C may be spaced apart from each other in the first direction to form a gap XG. For example, the inductance of the magnetic element 100C may be adjusted using the size of the gap XG. The larger the gap XG, the greater the decrease in the inductance. For example, the distance of the gap XG in the first direction may be 10 µm to 100 µm, but the embodiment is not necessarily limited thereto.

[0216] According to the embodiment, the size of the second through-hole TH2 may be proportional to the size of the gap XG. This is because, as the size of the gap XG increases, the amount of generated heat increases, necessitating rapid heat dissipation to the outside through the second through-hole TH2.

[0217] In addition, according to the embodiment, the length a1 or a2 of the second through-hole TH2 in the first direction may be greater than or equal to the length of the gap XG in the first direction.

[0218] In addition, according to the embodiment, the space SP between the upper coil 132 and the lower coil 134 shown in FIGs. 6, 20A, and 20B may communicate with the second through-hole TH2.

[0219] Furthermore, in order to ensure that heat in the magnetic element 100C is discharged through the second through-hole TH2 and the heat discharged through the second through-hole TH2 is effectively discharged to the outside, the second through-hole TH2 may overlap the gaps YG1 and YG2 in the third direction.

[0220] The bobbin unit 120C serves to secure the winding of the coil unit 130B and to insulate the coil unit 130B from the core unit 110C. Considering this, the coil unit 130B may be wound avoiding the place at which the central leg portions CL31 and CL32 are exposed due to the second through-hole TH2. If the central leg portions CL31 and CL32 are exposed through the second through-hole TH2, i.e., if at least a part of each of the central leg portions CL31 and CL32 overlaps the second through-hole TH2 in the horizontal direction, the upper coil 132 may be disposed above the second through-hole TH2 and the lower coil 134 may be disposed under the second through-hole TH2.

[0221] If the bobbin unit 120C is not disposed between the coil unit 130B and the core unit 110C, the magnetic element may become vulnerable to withstand voltage. Therefore, the coil unit 130B may be wound on the bobbin unit 120C such that the insulation creepage distance between the coil unit 130B and the core unit 110C is 5.5 mm or more.

[0222] In addition, the height of the second through-hole TH2 in the first direction may be determined so as to satisfy Equation 4 below. h × i − g × 1.1 ≥ a

[0223] Here, referring to FIGs. 6 and 21A, h indicates the height of the space SS1 or SS2 in which the coil unit 130A or 130B is wound between the central leg portion and the first or second outer leg portion in the first direction, i indicates the width of the space SS1 or SS2 in the third direction, g indicates the total sectional area SA of the coil present in the space SS1 or SS2, and a indicates the height a1 of the 2-1 through-hole TH21 in the first direction or the height a2 of the 2-2 through-hole TH22 in the first direction.

[0224] Furthermore, in order to dissipate heat generated in the central leg portions CL31 and CL32, the heights a1 and a2 of the second through-hole TH2 in the first direction must be greater than the length of the gap XG in the first direction, i.e., the distance by which the central leg portions are spaced apart from each other in the first direction. However, as the heights a1 and a2 of the second through-hole TH2 increase, the area in which the coil unit 130B can be wound may decrease. Considering this, the heights a1 and a2 of the second through-hole TH2 in the first direction may be 10% or more of the length of the gap XG in the first direction, but the embodiment is not limited thereto.

[0225] Furthermore, in order to facilitate heat dissipation, the total area of the second through-hole TH2 may be 50% or more of the area of the gap XG. That is, the size of the second through-hole TH2 may be determined considering Equation 5 below. a × b × n ≥ c × d 2 × 0.5

[0226] Here, a indicates the lengths a1 and a2 of the second through-hole TH2 (TH21 and TH22) in the first direction, b indicates the widths b1 and b2 of the second through-hole TH2 (TH21 and TH22) in the horizontal direction, n indicates the total number of second through-holes TH2 (TH21 and TH22), c indicates the length of the gap XG in the first direction, and d2 indicates the length of the gap XG in the third direction.

[0227] In addition, the total area of the second through-hole TH2 may be determined so as to satisfy Equation 6 below. a × b × n ≤ a × e + a × f

[0228] Here, e indicates the length of the fifth body portion B5 in the third direction, and f indicates the length of the fifth body portion B5 in the second direction. For example, the left side of Equation 6 may be 90% of the right side. This is because, if the left side of Equation 6 (the total area of the second through-hole TH2) exceeds 90% of the right side, there is a risk of the bobbin breaking.

[0229] In addition, as the horizontal widths b1 and b2 of the second through-hole TH2 (TH21 and TH22) increase, heat dissipation performance increases, but the widths b1 and b2 may be determined to prevent breakage of the bobbin unit 120C. This is because, if the widths b1 and b2 increase, the bobbin unit 120C may break.

[0230] In addition, according to the embodiment, at least one of the first gap YG1 between the plurality of upper core segments 112C1, 112C2, and 112C3 formed by the upper spacers USTR and USTL or the second gap YG2 between the plurality of lower core segments 114C1, 114C2, and 114C3 formed by the lower spacers LSTR and LSTL may overlap and communicate with the second through-hole TH2 in the third direction.

[0231] When air flows in the -y axis direction due to a fan for dissipating heat from the magnetic element, if the second through-hole TH2 as in the embodiment is not formed, there is no gap in the magnetic element, whereby air flows only outside the magnetic element, making it difficult to cool the interior of the magnetic element.

[0232] Furthermore, this phenomenon may be exacerbated if the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 are not spaced apart from each other but are attached to each other.

[0233] In contrast, according to the yet another embodiment described above, when air flows in the -y axis direction due to a fan for dissipating heat from the magnetic element 100C, heat generated from the central leg portions CL31 and CL32 of the core unit 110C due to fringing flux and heat of the coil 130B may be discharged outside the bobbin unit 120C through the second through-hole TH2. Particularly, according to the yet another embodiment, the heat discharged outside the bobbin unit 120C may be discharged to the outside through the first and second gaps YG1 and YG2 of the core unit 110C. Therefore, the magnetic element 100C according to the embodiment may be usefully employed for high-power modules generating significant heat, such as a 40kW-class fast-charging module. Furthermore, if the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 are not spaced apart from each other but are attached to each other, inductance fluctuates, whereby constant inductance is not guaranteed. Furthermore, if the upper spacers USTR and USTL or the lower spacers LSTR and LSTL are not provided, vibration between the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 may easily damage the core unit 110C.

[0234] However, according to the embodiment, the upper spacers USTR and USTL or the lower spacers LSTR and LSTL are disposed such that the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 are spaced apart from each other, whereby damage to the core unit 110C may be prevented while constant inductance is guaranteed. In addition, the upper spacers USTR and USTL or the lower spacers LSTR and LSTL may increase the surface area exposed to air contact in the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3, thereby further improving the heat dissipation effect. FIGs. 23A to 23C are plan views illustrating various outer upper protrusions of the magnetic element according to the embodiment.

[0235] The magnetic element shown in FIGs. 23A and 23C is identical to the magnetic element shown in FIG. 18A, except for different shapes of outer upper protrusions 40 and 44, and therefore duplicative descriptions thereof will be omitted. In addition, FIG. 23B corresponds to the magnetic element 100D shown in FIG. 19A, and therefore duplicative descriptions of identical parts will be omitted.

[0236] As described above, the outer upper protrusions 40, 44, CV1, CV2, CV3, CV4, CV5, CV6, CV7, and CV8 serve to cover the peripheral portions CPP1 and CPP2 of the coil unit 130B to prevent the peripheral portions CPP1 and CPP2 from escaping. As such, the outer upper protrusions 40, 44, CV1, CV2, CV3, CV4, CV5, CV6, CV7, and CV8 serve as anti-disengagement pieces that prevent disengagement of the coil unit 130B wound on the bobbin unit 120C. However, while the outer upper protrusions covering the outer portions COP1 and COP2 including the peripheral portions CPP1 and CPP2 and the central portion CCP of the coil unit provide the advantage of preventing disengagement of the coil unit, this may make it difficult for the coil unit to contact air, hindering effective heat dissipation from the coil unit.

[0237] Therefore, as shown in FIGs. 23A to 23C, the outer upper protrusions 40, CV5, 44, CV1, CV2, CV3, and CV4 cover at least a part of each of the peripheral portions CPP1 and CPP2 without covering the central portion CCP of the coil unit 130B, thereby minimizing the size of the outer upper protrusions 40, CV5, 44, CV1, CV2, CV3, and CV4 or determining the shape and position thereof.

[0238] Furthermore, as shown in FIGs. 23A and 23C, if outer corners 40P and 44P of the outer upper protrusions 40 and 44 are angularly formed, the coil may be damaged during winding of the coil. Therefore, as shown in FIG. 18A or 23B, the outer surfaces SP3 and SP5 of the outer upper protrusions CV1 and CV5 can be rounded to prevent coil damage during winding of the coil unit 130B.

[0239] FIG. 24A is a lower assembled perspective view of the magnetic element shown in FIG. 23A, and FIG. 24B is a lower assembled perspective view of the magnetic element 100D shown in FIGs. 19A and 23B.

[0240] Furthermore, in FIGs. 18A, 23A to 23C, 24A, and 24B, when air is introduced in the -y axis direction by the fan, the air flows in the directions indicated by the arrows. At this time, in FIGs. 23A, 23C, and 24A, the angular shape of each of the outer upper protrusions 40 and 44 may significantly impede the flow of air. However, as shown in FIGs. 18A, 23B, and 24B, if the outer surface of each of the outer upper protrusions CV1 and CV5 is curved, the air flow may be mitigated compared to FIGs. 23A, 23C, and 24A. Particularly, as shown in FIG. 18A, when the outer upper protrusion CV1 has a planar shape like a shark fin, the air flow becomes ideal, improving heat dissipation performance.

[0241] As described above, in the magnetic element 100C according to the yet another embodiment, outside air may flow smoothly into the central leg portions CL31 and CL32, thereby reducing the temperature of the magnetic element 100C by 10°C or more.

[0242] Furthermore, if the bobbin unit 120C is not disposed, sharp parts CP1A and CP1B of the corners of the core unit 114C may easily damage the coil unit 130B, whereby the core unit 114C and the coil unit 130B may be short circuited instead of being electrically insulated from each other, causing drive problems. In order to prevent this, according to the embodiment, the coil unit 130B is wound on the bobbin unit 120C, and then the core unit 110C is assembled in the bobbin unit 120C.

[0243] Hereinafter, with reference to FIG. 13, an assembly process of the magnetic element 100C according to the yet another embodiment will be described with reference to FIG. 13.

[0244] The coil unit 130B is wound so as to wrap around the outside of the fifth body portion B5 of the bobbin unit 120C. The coil unit 130B may be wound so as to correspond to the spaces between the outer leg portions OL311, OL312, OL321, and OL322 and the central leg portions CL31 and CL32 of each of the first core 112C and the second core 114C.

[0245] After the coil unit 130B is wound on the fifth body portion B5 of the bobbin unit 120C, the central leg portion CL32 of the second core 114C is inserted into the first through-hole TH1 formed in the fifth body portion B5 of the bobbin unit 120C. At this time, the coil unit 130B wound on the fifth body portion B5 of the bobbin unit 120C is inserted into the space between the central leg portion CL32 and each of the outer leg portions OL321 and OL322 of the second core 114C. The first core 112C may also be coupled to an upper part of the fifth body portion B5 of the bobbin unit 120C in the same manner as the second core 114C.

[0246] Although the above has been described based on the embodiments, these are merely illustrative and do not limit the present disclosure, and those skilled in the art will recognize that various modifications and applications not illustrated herein are possible without departing from the essential features of the present embodiments. For example, each of the components specifically shown in the embodiments may be practiced with variations. The differences with respect to such variations and applications are to be construed as being within the scope of the present disclosure as defined by the appended claims.[Mode for Disclosure]

[0247] The mode for disclosure has been sufficiently described in the aforementioned "Best Mode."[Industrial Applicability]

[0248] A magnetic element according to an embodiment may be used in instrument transformers, AC control panels, DC converters (DC-DC converters), step-up converters, step-down converters, etc.

Examples

Embodiment Construction

[0035]The present disclosure may be changed in various manners and may have various embodiments. Specific embodiments of the present disclosure will be described with reference to the drawings. However, the present disclosure is not limited to the specific embodiments, and it should be understood that the present disclosure includes all modifications, equivalents, or substitutions included in the idea and technical scope of the present disclosure.

[0036]Although terms including ordinal numbers, such as "first" and "second," may be used herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another component. For example, without departing from the scope of the present disclosure, a second component may be named a first component, and similarly, a first component may be named a second component. The term "and / or" includes any combination of a plurality of related listed items or any one ...

[Technical Field]

[0001] Embodiments relate to a magnetic element.[Background Art]

[0002] Various magnetic coupling devices, such as a transformer or a line filter, namely, a magnetic element, are incorporated into power supply devices for electronic equipment.

[0003] The transformer may be included in electronic equipment for various purposes. For example, the transformer may be used to perform an energy transfer function of transferring energy from one circuit to another. In addition, the transformer may be used to perform a step-up or step-down function of changing the magnitude of voltage. In addition, the transformer, which features only inductive coupling between the primary and secondary windings, thus directly forming no DC path, may be used for DC blocking and AC passing or for insulating separation between two circuits.

[0004] For a 20-kW large-capacity transformer, various cooling methods are used to dissipate heat generated from a coil and a core. For example, heat may be dissipated using air cooling with a fan. However, insufficient air inflow into the transformer may cause an issue with heat dissipation performance, and therefore research is ongoing to address this.[Disclosure][Technical Problem]

[0005] Embodiments provide a magnetic element with excellent cooling performance.[Technical Solution]

[0006] A magnetic element according to an embodiment may include a core unit including a first core and a second core disposed opposite the first core in a first direction, a bobbin unit at least partially disposed in the core unit, and a coil unit including an upper coil and a lower coil disposed on the bobbin unit, wherein the upper coil and the lower coil may be disposed spaced apart from each other in the first direction.

[0007] For example, each of the first and second cores may include a first body portion, a first outer leg portion protruding from one end of the first body portion in the first direction and extending in a second direction intersecting the first direction, a second outer leg portion protruding from the other end of the first body portion in the first direction and extending in the second direction, and a central leg portion protruding between the first outer leg portion and the second outer leg portion in the first direction and extending in the second direction.

[0008] For example, at least a part of the upper coil may be disposed between each of the first and second outer leg portions and the central leg portion of the first core, and at least a part of the lower coil may be disposed between each of the first and second outer leg portions and the central leg portion of the second core.

[0009] For example, the bobbin unit may include a second body portion on which the upper coil and the lower coil are disposed spaced apart from each other in the first direction, a first upper protrusion protruding from an upper end of the second body portion in a third direction intersecting each of the first and second directions, and a first lower protrusion protruding from a lower end of the second body portion in the third direction.

[0010] For example, the first upper protrusion may include a 1-1 upper protrusion disposed between the first outer leg portion and the central leg portion of the first core and a 1-2 upper protrusion disposed between the second outer leg portion and the central leg portion of the first core, the 1-2 upper protrusion being located on the opposite side of the 1-1 upper protrusion in the third direction.

[0011] For example, the first lower protrusion may include a 1-1 lower protrusion disposed between the first outer leg portion and the central leg portion of the second core and a 1-2 lower protrusion disposed between the second outer leg portion and the central leg portion of the second core, the 1-2 lower protrusion being located on the opposite side of the 1-1 lower protrusion in the third direction.

[0012] For example, the bobbin unit may further include a coil support portion protruding from the second body portion between the first upper protrusion and the first lower protrusion in a horizontal direction, the coil support portion being configured to support the upper coil.

[0013] For example, the first upper protrusion and the first lower protrusion may overlap each other in the first direction.

[0014] For example, the second body portion may include a first through-hole formed through the second body portion in the first direction, and the central leg portion of each of the first and second cores may be inserted into and disposed in the first through-hole.

[0015] For example, the first through-hole may have a first length in the first direction, the central leg portion of the first core may have a second length in the first direction, the central leg portion of the second core may have a third length in the first direction, and the sum of the second length and the third length may be less than the first length.

[0016] For example, the bobbin unit may include a second through-hole formed through the second body portion in the horizontal direction, and the second through-hole may overlap the space between the upper coil and the lower coil in the third direction.

[0017] For example, the length of the second through-hole in the first direction may be greater than the length of the space in the first direction.

[0018] For example, the second body portion may include an upper area between the first upper protrusion and the second through-hole and a lower area between the second through-hole and the first lower protrusion, the upper coil may overlap the upper area in the third direction, and the lower coil may overlap the lower area in the third direction.

[0019] For example, the second body portion may include first and second side portions opposite each other in the third direction with the first through-hole interposed therebetween and third and fourth side portions opposite each other in the second direction with the first through-hole interposed therebetween, the third and fourth side portions being located between the first side portion and the second side portion, and each of the first and second side portions may have a larger length than each of the third and fourth side portions in the horizontal direction.

[0020] For example, the second through-hole may include 2-1 through-holes disposed in each of the first and second side portions and 2-2 through-holes disposed in each of the third and third side portions.

[0021] For example, the number of the 2-1 through-holes may be greater than the number of the 2-2 through-holes.

[0022] For example, the bobbin unit may include a first lower central protrusion protruding from the lower end of the third side portion of the second body portion in the first and second directions, a first lower peripheral protrusion protruding from one end of the first lower protrusion in the first and second directions and disposed on the periphery of the first lower central protrusion, a second lower central protrusion protruding from the lower end of the fourth side portion of the second body portion in the first and second directions, and a second lower peripheral protrusion protruding from the other end of the first lower protrusion in the first and second directions and disposed on the periphery of the second lower central protrusion.

[0023] For example, a bottom surface of each of the first and second lower central protrusions and the first and second lower peripheral protrusions and a bottom surface of the first body portion of the second core may be disposed on the same horizontal plane.

[0024] For example, the thickness of each of the first and second lower central protrusions and the first and second lower peripheral protrusions in the first direction may be the same as the thickness of the first body portion of the second core in the first direction.

[0025] For example, each of the first and second lower peripheral protrusions may have a step.

[0026] For example, each of the first and second lower peripheral protrusions may include a stepped portion recessed in the first direction and having a third through-hole.

[0027] For example, first and second wires drawn out respectively from both ends of the lower coil may be supported by the second lower peripheral protrusion, and the second lower peripheral protrusion may have a larger surface area than the first lower peripheral protrusion.

[0028] For example, third and fourth wires drawn out respectively from both ends of the upper coil may overlap the first lower peripheral protrusion in the first direction.

[0029] For example, the first body portion of the second core may be received in a first space between the first lower central protrusion and the second lower central protrusion and a second space between the first lower peripheral protrusion and the second lower peripheral protrusion.

[0030] For example, the upper coil may be a primary coil, and the lower coil may be a secondary coil.

[0031] For example, the lower coil may be a primary coil, and the upper coil may be a secondary coil.

[0032] For example, the distance between the upper coil and the lower coil in the first direction may be 1 mm to 2 mm.[Advantageous Effects]

[0033] A magnetic element according to embodiments has excellent cooling performance and heat dissipation performance.[Description of Drawings]

[0034] FIG. 1 is an assembled perspective view of a magnetic element according to an embodiment. FIG. 2 is an exploded perspective view of the magnetic element shown in FIG. 1. FIG. 3 is a perspective view of the magnetic element shown in FIG. 1 with a first core removed. FIG. 4 is a perspective view of the magnetic element shown in FIG. 1 with a core unit removed. FIGs. 5A to 5G are, respectively, an upper perspective view, a lower perspective view, a front view, a rear view, a plan view, a bottom view, and a side view of a bobbin unit shown in FIG. 2. FIG. 6 is a sectional view taken along line I-I' of FIG. 1. FIG. 7 is an assembled perspective view of a magnetic element according to another embodiment. FIG. 8 is an exploded perspective view of the magnetic element shown in FIG. 7. FIG. 9 is a perspective view of the magnetic element shown in FIG. 7 with a first upper core segment removed. FIG. 10 is a perspective view of the magnetic element shown in FIG. 7 with a first core removed. FIG. 11 is a perspective view of the magnetic element shown in FIG. 7 with the first core and a second lower core segment removed. FIG. 12 is an assembled perspective view of a magnetic element according to a yet another embodiment. FIG. 13 is an exploded perspective view of the magnetic element shown in FIG. 12. FIG. 14 is a perspective view of the magnetic element shown in FIG. 12 with first and second upper core segments removed. FIG. 15 is a perspective view of the magnetic element shown in FIG. 12 with a first core removed. FIG. 16 is a perspective view of the magnetic element shown in FIG. 12 with the first core and a first lower core segment removed. FIGs. 17A to 17C are, respectively, an upper perspective view, a plan view, and a front view of a bobbin shown in FIG. 13. FIG. 18A is a plan view of a right corner of the magnetic element shown in FIG. 12, FIG. 18B is a plan view of a left corner of the magnetic element shown in FIG. 12 with a second outer upper protrusion removed, FIG. 18C is a combined plan view of a coil unit and a second core, and FIG. 18D is a plan view of another embodiment of the right corner of the magnetic element shown in FIG. 12. FIG. 19A is a plan view of a magnetic element according to a further embodiment, and FIG. 19B is an enlarged view of part 'A' of FIG. 19A. FIGs. 20A and 20B are, respectively, a side view and a front view of the magnetic element shown in FIG. 12. FIG. 21A is a combined perspective view of the bobbin and a core unit of the magnetic element shown in FIG. 12, and FIG. 21B is a perspective view of the magnetic element shown in FIG. 21A with the first core removed. FIG. 22 is a combined perspective view of the core unit shown in FIG. 13. FIGs. 23A to 23C are plan views illustrating various outer upper protrusions of the magnetic element according to the embodiment. FIG. 24A is a lower assembled perspective view of the magnetic element shown in FIG. 23A, and FIG. 24B is a lower assembled perspective view of the magnetic element shown in FIGs. 19A and 23B. [Best Mode]

[0035] The present disclosure may be changed in various manners and may have various embodiments. Specific embodiments of the present disclosure will be described with reference to the drawings. However, the present disclosure is not limited to the specific embodiments, and it should be understood that the present disclosure includes all modifications, equivalents, or substitutions included in the idea and technical scope of the present disclosure.

[0036] Although terms including ordinal numbers, such as "first" and "second," may be used herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another component. For example, without departing from the scope of the present disclosure, a second component may be named a first component, and similarly, a first component may be named a second component. The term "and / or" includes any combination of a plurality of related listed items or any one of a plurality of related listed items.

[0037] It should be understood that, when a component is referred to as being "connected to" or "coupled to" another component, it may be directly connected to or coupled to another component or intervening components may be present. In contrast, it should be understood that, when a component is referred to as being "directly connected to" or "directly coupled to" another component, there are no intervening components present.

[0038] In the following description of the embodiments, it will be understood that, when an element, such as a layer (film), an area, a pattern, or a structure, is referred to as being "on" or "under" another element, such as a substrate, a layer (film), an area, a pad, or a pattern, it can be "directly" on or under another element or can be formed such that an intervening element is also present. Reference to on / above or below / under each layer is given with reference to the drawings. In addition, the thickness or size of each layer (film), area, pattern, or structure in the drawings may be varied for clarity and convenience of description and is not necessarily indicative of actual size.

[0039] The terms used in the present application are provided only to described specific embodiments, and do not limit the present disclosure. Singular forms are intended to include plurality of forms as well, unless the context clearly indicates otherwise. In the present application, it should be understood that the terms "includes," "has," etc. specify the presence of stated features, numbers, steps, operations, elements, components, or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof.

[0040] All terms, including technical and scientific terms, have the same meanings as those commonly understood by one of ordinary skill in the art to which this disclosure pertains, unless defined otherwise. Commonly used terms, such as those defined in typical dictionaries, should be interpreted as being consistent with the contextual meaning of the relevant art, and are not to be construed in an ideal or overly formal sense unless expressly defined to the contrary.

[0041] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings, wherein identical or corresponding components are denoted by the same reference symbols regardless of drawing designation, and duplicative descriptions thereof will be omitted.

[0042] In addition, some embodiments are described using a Cartesian coordinate system (X-axis, Y-axis, Z-axis), and in the Cartesian coordinate system, the X-axis, Y-axis, and Z-axis shown in each figure are orthogonal to each other, but the present disclosure is not limited thereto. The X-axis, Y-axis, and Z-axis may intersect each other. Hereinafter, for convenience of description, the Z-axis direction is referred to as a vertical direction, and each of the X-axis direction and the Y-axis direction is referred to as a horizontal direction. Furthermore, the X-axis direction is referred to as a first direction, the Y-axis direction is referred to as a second direction, and the Z-axis direction is referred to as a third direction.

[0043] Hereinafter, a magnetic element 100A according to an embodiment will be described in detail with reference to the accompanying drawings.

[0044] FIG. 1 is an assembled perspective view of a magnetic element 100A according to an embodiment, FIG. 2 is an exploded perspective view of the magnetic element 100A shown in FIG. 1, FIG. 3 is a perspective view of the magnetic element 100A shown in FIG. 1 with a first core 112A removed, FIG. 4 is a perspective view of the magnetic element 100A shown in FIG. 1 with a core unit 110A removed, FIGs. 5A to 5G are, respectively, an upper perspective view, a lower perspective view, a front view, a rear view, a plan view, a bottom view, and a side view of a bobbin unit 120A shown in FIG. 2, and FIG. 6 is a sectional view taken along line I-I' of FIG. 1.

[0045] The magnetic element 100A according to the embodiment may include a core unit 110A, a bobbin unit 120A, and a coil unit 130A.

[0046] The core unit 110A may have the nature of a magnetic circuit and serve as a path for magnetic flux. The core unit 110A may include a first core 112A and a second core 114A. The first core 112A and the second core 114A may be disposed opposite each other in a first direction.

[0047] The first core 112A may include a first body portion B11, a first outer leg portion OL11, a second outer leg portion OL12, and a central leg portion CL1, and the second core 114A may include a first body portion B12, a first outer leg portion OL21, a second outer leg portion OL22, and a central leg portion CL2.

[0048] Each of the first outer leg portions OL11 and OL21 may protrude from one end of a corresponding one of the first body portions B11 and B12, which may be flat, in the first direction, and may extend in a second direction intersecting the first direction.

[0049] Each of the second outer leg portions OL12 and OL22 may protrude from the other end of a corresponding one of the first body portions B11 and B12 in the first direction, and may extend in the second direction.

[0050] Each of the central leg portions CL1 and CL2 may protrude in the first direction between a corresponding one of the first outer leg portions OL11 and OL21 and a corresponding one of the second outer leg portions OL12 and OL22, and may extend in the second direction.

[0051] The first core 112A may be disposed on the second core 114A. The first and second cores 112A and 114A may have symmetrical shapes or asymmetrical shapes. However, for the sake of convenience in the following description, the first and second cores are assumed to have symmetrical shapes.

[0052] When the first core 112A and the second core 114A are vertically coupled to each other, the first and second outer leg portions OL11 and OL12 and the central leg portion CL1 of the first core 112A are opposite the first and second outer leg portions OL21 and OL22 and the central leg portion CL2 of the second core 114A, respectively. At this time, a gap of a predetermined distance may be formed between at least some of the opposing outer leg pairs or central leg pairs. In the case of FIG. 6, the predetermined distance is illustrated as '0', but the embodiment is not limited thereto. For example, the predetermined distance of the gap may be 10 µm to 100 µm, but the embodiment is not necessarily limited thereto. For example, the predetermined distance of the gap may be 100 µm and may be set variously depending on the embodiment.

[0053] In addition, the core unit 110A (112A and 114A) may include a magnetic material, such as iron or ferrite, but the embodiment is not necessarily limited thereto.

[0054] Meanwhile, at least a part of the bobbin unit 120A may be disposed in the core unit 110A.

[0055] The coil unit 130A may include an upper coil 132 and a lower coil 134 disposed, i.e., wound, on the bobbin unit 120A. Referring to FIG. 6, at least a part of the upper coil 132 may be disposed between each of the first and second outer leg portions OL11 and OL12 and the central leg portion CL1 of the first core 112A, and at least a part of the lower coil 134 may be disposed between each of the first and second outer leg portions OL21 and OL22 and the central leg portion CL2 of the second core 114A.

[0056] In the case of FIG. 6, each of the upper coil 132 and the lower coil 134 is shown as contacting a second body portion B2 of the bobbin unit 120A described later, but the embodiment is not limited thereto. That is, according to another embodiment, each of the upper coil 132 and the lower coil 134 may be disposed spaced apart from the second body portion B2 in a third direction. That is, each of the upper coil 132 and the lower coil 134 may be disposed closer to the outer leg portions OL11, OL12, OL21, and OL22 than to the central leg portions CL1 and CL2.

[0057] According to the embodiment, the upper coil 132 and the lower coil 134 may be disposed spaced apart from each other in the first direction. That is, as shown in FIG. 6, the upper coil 132 and the lower coil 134 may be disposed spaced apart from each other with a space SP therebetween. If the distance by which the upper coil 132 and the lower coil 134 are spaced apart from each other in the first direction, i.e., the width X5 of the space SP in the first direction, is less than 1 mm, short circuit may occur between the upper coil 132 and the lower coil 134. If the distance is greater than 2 mm, the area available for winding may decrease, making it difficult to achieve desired power capacity. Therefore, the width X5 may be 1 mm to 2 mm, but the embodiment is not limited thereto.

[0058] According to an embodiment, the upper coil 132 may be a primary coil, and the lower coil 134 may be a secondary coil. According to another embodiment, the lower coil 134 may be a primary coil, and the upper coil 132 may be a secondary coil.

[0059] Each of the upper coil 132 and the lower coil 134 may include a plurality of conductive wires wound so as to form a plurality of turns around a first through-hole TH1.

[0060] Each of the upper coil 132 and the lower coil 134 may be a plurality of conductive wires (or a plurality of windings) formed by winding a rigid conductive metal, such as copper conductive wire, in a spiral form or a planar spiral form a plurality of times, but the embodiment is not necessarily limited thereto. For example, enameled wire (USTC wire) wrapped with fiber yarn, Litz wire, triple insulated wire (TIW), etc. may be applied to at least one of the upper coil 132 or the lower coil 134.

[0061] Hereinafter, the configuration of the bobbin unit 120A will be described with reference to the accompanying drawings.

[0062] The bobbin unit 120A may include a second body portion B2, a first upper protrusion UP1, and a first lower protrusion DP1.

[0063] The upper coil 132 and the lower coil 134 may be disposed on the second body portion B2 so as to be spaced apart from each other in the first direction.

[0064] As shown in FIG. 5C, the first upper protrusion UP1 may protrude from upper ends UE1 and UE2 of the second body portion B2 not only in a second direction but also in the third direction intersecting the first and second directions.

[0065] The first upper protrusion UP1 may include 1-1 and 1-2 upper protrusions UP11 and UP12. The 1-1 upper protrusion UP11 may protrude from the upper end UE1 of the second body portion B2 in the second and third directions, and may be disposed between the first outer leg portion OL11 and the central leg portion CL1 of the first core 112A. The 1-2 upper protrusion UP12 may protrude from the upper end UE2 of the second body portion B2 in the second and third directions, and may be disposed between the second outer leg portion OL12 and the central leg portion CL1 of the first core 112A. The 1-2 upper protrusion UP12 may be located on the opposite side of the 1-1 upper protrusion UP11 in the third direction.

[0066] The first upper protrusion UP1 disposed in this manner may perform the role of not only supporting the first core 112A but also preventing upward disengagement of the upper coil 132 wound on a fifth body portion B5.

[0067] The first lower protrusion DP1 may protrude from a lower end of the second body portion B2 in the third direction. The first lower protrusion DP1 may include 1-1 and 1-2 lower protrusions DP11 and DP12.

[0068] The 1-1 lower protrusion DP11 may be disposed between the first outer leg portion OL21 and the central leg portion CL2 of the second core 114A, and the 1-2 lower protrusion DP12 may be disposed between the second outer leg portion OL22 and the central leg portion CL2 of the second core 114A. The 1-2 lower protrusion DP12 may be disposed on the opposite side of the 1-1 lower protrusion DP11 in the third direction.

[0069] The first lower protrusion DP1 disposed in this manner may perform the role of not only supporting the lower coil 134 but also preventing downward disengagement of the lower coil 134 wound on the fifth body portion B5.

[0070] According to the embodiment, the first upper protrusion UP1 and the first lower protrusion DP1 may overlap in the first direction to form a space in which the upper coil 132 and the lower coil 134 are received.

[0071] In addition, the bobbin unit 120A may further include a coil support portion 122. The coil support portion 122 protrudes horizontally from the second body portion B2 between the first upper protrusion UP1 and the first lower protrusion DP1 to support the upper coil 132.

[0072] According to an embodiment, as shown, the coil support portion 122 may be disposed at a corner of the second body portion B2.

[0073] According to another embodiment, referring to FIG. 5C, the coil support portion 122 may be disposed in an area 122K immediately above a 2-2 through-hole TH22 instead of the corner of the second body portion B2.

[0074] In addition, although the coil support portion 122 may be disposed above the 2-2 through-hole TH22, as shown, the coil support portion may be disposed so as to horizontally overlap the 2-2 through-hole TH22 or disposed under the 2-2 through-hole TH22. For example, unlike what is shown in FIG. 5D, the coil support portion 122 and the 2-2 through-hole TH22 may be disposed on an imaginary horizontal line HL. However, the embodiment is not limited to a specific position and form in which the coil support portion 122 is disposed as long as it is possible to support the upper coil 132.

[0075] In addition, the bobbin unit 120A may further include a first through-hole TH1. The first through-hole TH1 may be formed through the second body portion B2 in the first direction, and the central leg portions CL1 and CL2 of the first core 112A and the second core 114A may be inserted into and disposed in the first through-hole TH1.

[0076] Referring to FIG. 5G, the first through-hole TH1 has a first length X1 in the first direction, and referring to FIG. 2, the central leg portion CL1 of the first core 112A may have a second length X2 in the first direction, and the central leg portion CL2 of the second core 114A may have a third length X3 in the first direction.

[0077] According to an embodiment, as shown in FIG. 6, the sum of the second length X2 and the third length X3 may be equal to the first length X1.

[0078] According to another embodiment, the sum of the second length X2 and the third length X3 may be less than the first length X1.

[0079] In addition, the bobbin unit 120A may further include a second through-hole TH2 (TH21 and TH22). The second through-hole TH2 may be formed through the second body portion B2 in the second or third direction. For example, the second through-hole TH2 may include a 2-1 through-hole TH21 formed through the second body portion B2 in the third direction and a 2-2 through-hole TH22 formed through the second body portion B2 in the second direction.

[0080] According to the embodiment, the second through-hole TH2 may overlap the space SP between the upper coil 132 and the lower coil 134 shown in FIG. 6 in the second or third direction. To this end, the position of the coil support portion 122 may be determined.

[0081] According to the embodiment, the length X4 of the second through-hole TH2 in the first direction may be greater than the length X5 of the space SP in the first direction. Therefore, at least one of the upper coil 132 or the lower coil 134 may overlap the second through-hole TH2 in the second or third direction. For example, the length X4 may be 1 mm to 5 mm, but the embodiment is not limited thereto.

[0082] In addition, referring to FIG. 5G, the second body portion B2 may include an upper area UA and a lower area LA. The upper area UA may be defined as the area located between the first upper protrusion UP1 (UP11 and UP12) and the second through-hole TH2, and the lower area LA may be defined as the area located between the second through-hole TH2 and the first lower protrusion DP11 and DP12.

[0083] The upper coil 132 may overlap the upper area UA in the third direction, and the lower coil 134 may overlap the lower area LA in the third direction.

[0084] Meanwhile, the second body portion B2 may further include first to fourth side portions S1 to S4.

[0085] The first and second side portions S1 and S2 may be opposite each other in the third direction with the first through-hole TH1 interposed therebetween, and the third and fourth side portions S3 and S4 may be opposite each other in the second direction with the first through-hole TH1 interposed therebetween and may be located between the first side portion S1 and the second side portion S2.

[0086] The second through-hole TH2 may include a 2-1 through-hole TH21 disposed in each of the first and second side portions S1 and S2 and formed through the second body portion B2 in the third direction and a 2-2 through-hole TH22 disposed in each of the third and fourth side portions S3 and S4 and formed through the second body portion B2 in the second direction.

[0087] The 2-1 through-holes TH21 and the 2-2 through-holes TH22 may have the same size or number, but the embodiment is not limited to a specific size or number of the second through-holes TH2 (TH21 and TH22).

[0088] As shown, in the horizontal direction, each of the first and second side portions S1 and S2 has a larger length than each of the third and fourth side portions S3 and S4. Therefore, when the sizes of the 2-1 and 2-2 through-holes TH21 and TH22 are the same, the number of 2-1 through-holes TH21 disposed in each of the first and second side portions S1 and S2 may be greater than the number of 2-2 through-holes TH22 disposed in each of third and fourth side portions S3 and S4. For example, as shown, the number of 2-1 through-holes TH21 may be four and the number of 2-2 through-holes TH22 may be two, but the embodiment is not limited thereto.

[0089] According to another embodiment, the number of 2-1 through-holes TH21 and the number of 2-2 through-holes TH22 may be the same, and the size of the 2-1 through-hole TH21 may be greater than the size of the 2-2 through-hole TH22.

[0090] In addition, the bobbin unit 120A may include first and second lower central protrusions LCP1 and LCP2, a first lower peripheral protrusion LPP11 and LPP12, and a second lower peripheral protrusion LPP21 and LPP22.

[0091] The first lower central protrusion LCP1 protrudes from a lower end of the third side portion S3 of the second body portion B2 in the first and second directions, and the second lower central protrusion LCP2 protrudes from a lower end of the fourth side portion S4 of the second body portion B2 in the first and second directions. The first and second lower central protrusions LCP1 and LCP2 serve to support the lower coil 134, as shown in FIGs. 1, 3, and 4.

[0092] The first lower peripheral protrusion LPP11 and LPP12 protrudes from one end of the first lower protrusion DP11 and DP12 in the first and second directions and is disposed on the periphery of the first lower central protrusion LCP1. That is, the 1-1 lower peripheral protrusion LPP11 protrudes from one end of the 1-1 lower protrusion DP11 in the first and second directions and is disposed on one side of the periphery of the first lower central protrusion LCP1, and the 1-2 lower peripheral protrusions LPP12 protrudes from one end of the 1-2 lower protrusions DP12 in the first and second directions and is disposed on the other side of the periphery of the first lower central protrusion LCP1.

[0093] The second lower peripheral protrusion LPP21 and LPP22 protrudes from the other end of the first lower protrusion DP11 and DP12 in the first and second directions and is disposed on the periphery of the second lower central protrusion LCP2. That is, the 2-1 lower peripheral protrusion LPP21 protrudes from the other end of the 1-1 lower protrusion DP11 in the first and second directions and is disposed on one side of the periphery of the second lower central protrusion LCP2, and the 2-2 lower peripheral protrusion LPP22 protrudes from the other end of the 1-2 lower protrusion DP12 in the first and second directions and is disposed on the other side of the periphery of the second lower central protrusion LCP2.

[0094] Referring to FIGs. 5C and 5D, a bottom surface BSC1 of the first lower central protrusion LCP1, a bottom surface BSC2 of the second lower central protrusion LCP2, a bottom surface BSP11 of the 1-1 lower peripheral protrusion LPP11, a bottom surface BSP12 of the 1-2 lower peripheral protrusion LPP12, a bottom surface BSP21 of the 2-1 lower peripheral protrusion LPP21, a bottom surface BSP22 of the 2-2 lower peripheral protrusion LPP22, and a bottom surface 114BS of the first body portion 114A of the second core 114A may be disposed on the same horizontal plane.

[0095] In addition, the thickness T1 of each of the first lower central protrusion LCP1 and the first lower peripheral protrusion LPP11 and LPP12 in the first direction, the thickness T2 of each of the second lower central protrusion LCP2 and the second lower peripheral protrusion LPP21 and LPP22 in the first direction, and the thickness T3 of the first body portion B12 of the second core 114A in the first direction may be the same.

[0096] Therefore, the first body portion B12 of the second core 114A may be received in a first space between the first lower central protrusion LCP1 and the second lower central protrusion LCP2 opposite each other in the second direction and a second space between the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22 opposite each other in the second direction.

[0097] In addition, according to the embodiment, each of the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22 has a step. In this case, the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22 may respectively include stepped portions STP1 to STP4, each of which is recessed in the first direction and has a third through-hole TH3.

[0098] Although not shown, the magnetic element 100A according to the embodiment may be connected to a printed circuit board (PCCB). In this case, the third through-hole TH3 of the magnetic element 100A may be a part into which a screw (not shown) that fastens the PCB and the magnetic element 100A to each other is fitted. In this case, the first and second lower central protrusions LCP1 and LCP2 may serve to prevent bending of the magnetic element 100A when the screw is fastened. To this end, the first and second lower central protrusions LCP1 and LCP2, the first lower peripheral protrusion LPP11 and LPP12, and the second lower peripheral protrusion LPP21 and LPP22 may be formed integrally.

[0099] According to the embodiment, as shown in FIGs. 5C and 5D, the width of a lower side of the bobbin unit 120A in the third direction may be greater than the width of an upper side of the bobbin unit 120A in the third direction.

[0100] Referring to FIGs. 3 and 4, first and second wires W1 and W2 drawn out respectively from both ends of the lower coil 134 are supported by the second lower peripheral protrusion LPP21 and LPP22. On the other hand, third and fourth wires W3 and W4 drawn out respectively from both ends of the upper coil 132 overlap the first lower peripheral protrusion LPP11 and LPP12 in the first direction but are not supported by the first lower peripheral protrusion LPP11 and LPP12.

[0101] In this case, each of a plurality of terminal pins (or connection ends) TM1 to TM4 may be disposed at a distal end of a corresponding one of the first to fourth wires W1 to W4. The plurality of terminal pins may be connected to a power supply unit and parts.

[0102] In order for the second lower peripheral protrusion LPP21 and LPP22 to stably support the first and second wires W1 and W2, the second lower peripheral protrusion LPP21 and LPP22 may have a larger surface area than the first lower peripheral protrusion LPP11 and LPP12. That is, referring to FIG. 5F, the surface area SA11 of the 1-1 lower peripheral protrusion LPP11, the surface area SA12 of the 1-2 lower peripheral protrusion LPP12, the surface area SA21 of the 2-1 lower peripheral protrusion LPP21, and the surface area SA22 of the 2-2 lower peripheral protrusion LPP22 are given by Equation 1 below. SA 11 = Y 1 × Z 11 SA 12 = Y 1 × Z 12 SA 21 = Y 2 × Z 21 SA 22 = Y 2 × Z 21

[0103] Here, Y1 indicates the length of the first lower peripheral protrusion LPP11 and LPP12 in the second direction, Y2 indicates the length of the second lower peripheral protrusion LPP21 and LPP22 in the second direction, Z11 indicates the length of the 1-1 lower peripheral protrusion LPP11 in the third direction, Z12 indicates the length of the 1-2 lower peripheral protrusion LPP12 in the third direction, Z21 indicates the length of the 2-1 lower peripheral protrusion LPP21 in the third direction, and Z22 indicates the length of the 2-2 lower peripheral protrusion LPP22 in the third direction.

[0104] These surface areas SA11, SA12, SA21, and SA22 may have the relationship shown in Equation 2 below. SA 11 < SA 21 SA 11 < SA 22 SA 12 < SA 21 SA 12 < SA 22

[0105] Hereinafter, a magnetic element 100B according to another embodiment will be described with reference to the accompanying drawings.

[0106] FIG. 7 is an assembled perspective view of a magnetic element 100B according to another embodiment, FIG. 8 is an exploded perspective view of the magnetic element 100B shown in FIG. 7, FIG. 9 is a perspective view of the magnetic element 100B shown in FIG. 7 with a first upper core segment 112B1 removed, FIG. 10 is a perspective view of the magnetic element 100B shown in FIG. 7 with a first core 112B removed, and FIG. 11 is a perspective view of the magnetic element 100B shown in FIG. 7 with the first core 112B and a second lower core segment 114B1 removed.

[0107] The magnetic element 100B according to the other embodiment has a configuration in which at least one of first and second cores 112B and 114B is divided in the second direction, unlike the magnetic element 100A according to the embodiment. Consequently, except that the shape of a core unit 110B differs from that of the core unit 110A, the description of the magnetic element 100A according to the embodiment may apply to the magnetic element 100B according to the other embodiment shown in FIGs. 7 to 11. Therefore, identical parts are denoted by the same reference numerals, and duplicative descriptions thereof will be omitted.

[0108] According to the other embodiment, the magnetic element 100B may include a core unit 110B, a bobbin unit 120B, and a coil unit 130A.

[0109] The core unit 110B may include first and second cores 112B and 114B.

[0110] The first core 112B may include a plurality of upper core segments divided in the second direction, and the second core 114B may include a plurality of lower core segments divided in the second direction and disposed opposite the plurality of upper core segments in the first direction.

[0111] For example, as shown, each of the first core 112B and the second core 114B may be divided into two segments, but the embodiment is not limited thereto, and each of the first core and the second core may be divided into three or more segments. In the shown case, the first core 112B may be divided into first and second upper core segments 112B1 and 112B2, and the second core 114B may be divided into first and second lower core segments 114B1 and 114B2.

[0112] Hereinafter, each of the first core 112B and the second core 114B will be described as being divided into two segments, but the following description may also apply to the case in which each of the first core 112B and the second core 114B are divided into three or more segments as described later.

[0113] The first core 112B may include first and second upper core segments 112B1 and 112B2. Each of the first and second upper core segments 112B1 and 112B2 may include a first body portion B11, a first outer leg portion OL111, a second outer leg portion OL112, and a central leg portion CL11.

[0114] The second core 114B may include first and second lower core segments 114B1 and 114B2. Each of the first and second lower core segments 114B1 and 114B2 may include a first body portion B12, a first outer leg portion OL221, a second outer leg portion OL222, and a central leg portion CL22.

[0115] Each of the first outer leg portions OL111 and OL221 may protrude from one end of a corresponding one of the first body portions B11 and B12 in the first direction, and may extend in the second direction. Each of the second outer leg portions OL112 and OL222 may protrude from the other end of a corresponding one of the first body portions B11 and B12 in the first direction, and may extend in the second direction. Each of the central leg portions CL11 and CL22 may protrude in the first direction between a corresponding one of the first outer leg portions OL111 and OL221 and a corresponding one of the second outer leg portions OL112 and OL222, and may extend in the second direction.

[0116] Meanwhile, the bobbin unit 120B may include a second body portion B2, a first upper protrusion UP1, and a first lower protrusion DP1.

[0117] The coil unit 130A may be disposed on the second body portion B2, and may include an upper coil 132 and a lower coil 134 wound on the second body portion B2 so as to be spaced apart from each other in the first direction. The upper coil 132 is one of a primary coil and a secondary coil, and the lower coil 134 may be the other of the primary coil and the secondary coil.

[0118] Alternatively, the primary coil and the secondary coil may be disposed on the bobbin unit 120B without being spaced apart in the first direction, unlike the coil unit 130A of the magnetic element 100A according to the embodiment. The magnetic element 100B according to the other embodiment is not limited to a specific configuration in which the primary coil and secondary coil are disposed.

[0119] The first upper protrusion UP1 may include a 1-1 upper protrusion UP11 and a 1-2 upper protrusion UP12.

[0120] The 1-1 upper protrusion UP11 may be disposed between the first outer leg portion OL111 and the central leg portion CL11 of each of the first and second upper core segments 112B1 and 112B2, and the 1-2 upper protrusion UP12 may be disposed between the second outer leg portion OL112 and the central leg portion CL11 of each of the first and second upper core segments 112B1 and 112B2 and located on the opposite side of the 1-1 upper protrusion UP11 in the third direction. Consequently, the 1-1 and 1-2 upper protrusions UP11 and UP12 serve to support the plurality of upper core segments 112B1 and 112B2.

[0121] The first lower protrusion DP1 may include 1-1 and 1-2 lower protrusions DP11 and DP12. The 1-1 lower protrusion DP11 may be disposed between the first outer leg portion OL221 and the central leg portion CL22 of each of the first and second lower core segments 114B1 and 114B2, and the 1-2 lower protrusion DP12 may be disposed between the second outer leg portion OL222 and the central leg portion CL22 of each of the first and second lower core segments 114B1 and 114B2 and located on the opposite side of the 1-1 lower protrusion DP11 in the third direction.

[0122] In addition, the central leg portion CL11 of each of the first and second upper core segments 112B1 and 112B2 and the central leg portion CL22 of each of the first and second lower core segments 114B1 and 114B2 may be inserted into and disposed in the first through-hole TH1 of the second body portion B2 shown in FIGs. 5A to 5G. The description of the sizes of the central leg portions CL1 and CL2 and the first through-hole TH1 may also apply to the central leg portions CL11 and CL22, and duplicative descriptions thereof will be omitted.

[0123] In addition, duplicative descriptions of parts of the bobbin unit 120B of the magnetic element 100B identical to those of the bobbin unit 120A of the magnetic element 100A according to the embodiment will be omitted, and only different parts will be described.

[0124] In the magnetic element 100B according to the other embodiment, each of the first and second cores 112A and 114B may be divided in the second direction and each of the plurality of divided upper core segments and the plurality of divided lower core segments is spaced apart from each other by a uniform distance, unlike the magnetic element 100A according to the embodiment.

[0125] To this end, according to the embodiment, the magnetic element 100B may further include first and second adhesive portions AD1, AD2, AD3, and AD4.

[0126] The first and second adhesive portions AD1 and AD2 adhere a bottom surface BS1 of the first body portion B11 of each of the first and second upper core segments 112A and 112B to an upper surface TSF of the first upper protrusion UP1 to maintain a uniform distance between the first and second upper core segments 112B1 and 112B2.

[0127] The third and fourth adhesive portions AD3 and AD4 adhere an upper surface BS2 of the first body portion B12 of each of the first and second lower core segments 114A and 114B to a lower surface ST3 of the first lower protrusion DP1 shown in FIG. 5F to maintain a uniform distance between the first and second lower core segments 114B1 and 114B2.

[0128] According to another embodiment, since each of the first and second cores 112A and 114B of the magnetic element 100B is divided in the second direction, the magnetic element 100B may include first to fourth stoppers (or spacers) ST1, ST2, ST3, and ST4 in order to maintain a uniform distance between the plurality of divided upper core segments and between the plurality of divided lower core segments.

[0129] The first and second stoppers ST1 and ST2 are disposed on an upper surface of the first upper protrusion UP1 (UP11 and UP12) between the first body portions B11 of the first and second upper core segments 112B1 and 112B2 to maintain a uniform distance between the first and second upper core segments 112B1 and 112B2.

[0130] The second and fourth stoppers ST3 and ST4 are disposed on a lower surface of the first lower protrusion DP1 (DP11 and DP12) between the first body portions B12 of the first and second lower core segments 114B1 and 114B2 to maintain a uniform distance between the first and second lower core segments 114B1 and 114B2.

[0131] According to the embodiment, as shown, the magnetic element 100B may include both the first to second adhesive portions AD1 to AD4 and the first to second stoppers ST1 to ST4, may include only the first to second adhesive portions AD1 to AD4, or may include only the first to second stoppers ST1 to ST4.

[0132] According to the embodiment, the plurality of upper core segments 112B1 and 112B2 may be disposed spaced apart from each other by a first gap GS1 in the second direction, and the plurality of lower core segments 114B1 and 114B2 may be disposed spaced apart from each other by a second gap GS2 in the second direction.

[0133] According to the embodiment, the widths of the first gap GS1 and the second gap GS2 in the horizontal direction may be the same. For example, if the width of each of the first gap GS1 and the second gap GS2 in the second direction is less than 0.1 mm, an inlet through which air flows from the outside into the magnetic element 100B becomes narrower, making it difficult for the outside air to remove the heat in the magnetic element 100B. If the width is greater than 1.0 mm, the first gap GS1 and the second gap GS2 may generate fringing flux, increasing magnetic flux and potentially affecting heat generation. Therefore, the width of each of the first gap GS1 and the second gap GS2 in the second direction may be 0.1 mm to 1.0 mm, but the embodiment is not limited thereto.

[0134] In the magnetic element 100A according to the embodiment, the primary coil and the secondary coil are spaced apart from each other in the first direction to form an air flow path between the primary coil and the secondary coil, enabling effective removal of the heat generated by the coils, whereby it is possible to improve heat dissipation performance, i.e., cooling performance.

[0135] In addition, the plurality of second through-holes TH2 and the space SP between the primary coil and the secondary coil are disposed so as to overlap each other in the third direction, whereby air introduced through the second through-holes TH2 easily flows into the space SP. Consequently, a fan cooling path is formed, thereby further improving the cooling performance.

[0136] In addition, since the first body portion B12 of the second core 114A or 114B is received in a first space between the first lower central protrusion LCP1 and the second lower central protrusion LCP2 and a second space between the first lower peripheral protrusion LPP11 and LPP12 and the second lower peripheral protrusion LPP21 and LPP22, a separate space for receiving the second core 114A or 114B is not required, whereby the size of the magnetic element 100A or 100B may be reduced, enabling miniaturization.

[0137] Furthermore, if each of the first and second cores 112A and 114A is not divided, the amount of air that flows into the magnetic element 100A may not be sufficient. However, in the magnetic element 100B according to the other embodiment, since the first and second cores 112B and 114B are divided in the second direction and disposed spaced apart from each other with the gaps GS1 and GS2 therebetween, sufficient air may flow from the outside into the magnetic element 100B through the gaps GS1 and GS2 to remove heat, thereby further improving the cooling performance. The cooling performance advantage becomes more pronounced as the magnetic element 100B increases in size.

[0138] Hereinafter, a magnetic element 100C according to another embodiment will be described with reference to the accompanying drawings.

[0139] FIG. 12 is an assembled perspective view of a magnetic element 100C according to a yet another embodiment, FIG. 13 is an exploded perspective view of the magnetic element 100C shown in FIG. 12, FIG. 14 is a perspective view of the magnetic element 100C shown in FIG. 12 with first and second upper core segments 112C1 and 112C2 removed, FIG. 15 is a perspective view of the magnetic element 100C shown in FIG. 12 with a first core 112C removed, FIG. 16 is a perspective view of the magnetic element 112C shown in FIG. 12 with the first core 112C and a first lower core segment 114C1 removed, and FIGs. 17A to 17C are, respectively, an upper perspective view, a plan view, and a front view of a bobbin 120C shown in FIG. 13.

[0140] FIG. 6 corresponds to a sectional view taken along line II-II' of FIG. 12.

[0141] The magnetic element 100C according to the yet another embodiment has a configuration in which at least one of first and second cores 112C and 114C is divided in the second direction, unlike the magnetic element 100A according to the embodiment.

[0142] In addition, while the magnetic element 100B according to the other embodiment has a configuration in which each of the first and second cores 112B and 114B is divided into two segments in the second direction, the magnetic element 100C according to the yet another embodiment has a configuration in which each of the first and second cores 112C and 114C is divided into three segments in the second direction.

[0143] In addition, spacers USTL, USTR, LSTR, and LSTL disposed on the bobbin 120C of the magnetic element 100C according to the yet another embodiment differ in form and position from the spacers ST1, ST2, ST3, and ST4 of the magnetic element 100B according to the other embodiment.

[0144] In addition, the magnetic element 100C according to the yet another embodiment does not include a coil support portion 122, unlike the magnetic elements 100B and 100C according to the embodiment and the other embodiment.

[0145] In addition, a second upper protrusion UP2 of the magnetic element 100C according to the yet another embodiment has a different shape from the first upper protrusion UP1 of each of the magnetic elements 100A and 100B according to the embodiment and the other embodiment.

[0146] As described above, the magnetic element 100C according to the yet another embodiment has several different features from the magnetic elements 100A and 100B according to the embodiment and the other embodiment. Therefore, parts of the magnetic element 100C identical to parts of each of the magnetic elements 100A and 100B according to the embodiment and the other embodiment are denoted by the same reference numerals, duplicative descriptions thereof will be omitted, and only different parts will be described. That is, the description of the magnetic elements 100A and 100B according to the aforementioned embodiments may apply to the undescribed parts of the magnetic element 100C.

[0147] According to the yet another embodiment, the magnetic element 100C may be constituted by a core unit 110C, a bobbin unit 120C, and a coil unit 130B.

[0148] The core unit 110C may include first and second cores 112C and 114C.

[0149] The first core 112C may include a plurality of upper core segments divided in the second direction, and the second core 114C may include a plurality of lower core segments divided in the second direction and disposed opposite the plurality of upper core segments in the first direction.

[0150] For example, as shown, each of the first core 112C and the second core 114C may be divided into three segments, but the embodiment is not limited thereto, and each of the first core and the second core may be divided into four or more segments. In the shown case, the first core 112C may be divided into first to third upper core segments 112C1, 112C2, and 112C3, and the second core 114C may be divided into first to third lower core segments 114C1, 114C2, and 114C3.

[0151] Hereinafter, each of the first core 112C and the second core 114C will be described as being divided into three segments, but the following description may also apply to the case in which each of the first core 112CB and the second core 114C is divided into four or more segments.

[0152] Each of the first to third upper core segments 112C1, 112C2, and 112C3 may include a third body portion B3, a first outer leg portion OL311, a second outer leg portion OL312, and a central leg portion CL31.

[0153] Each of the first to third lower core segments 114C1, 114C2, and 114C3 may include a fourth body portion B4, a first outer leg portion OL321, a second outer leg portion OL322, and a central leg portion CL32.

[0154] The first outer leg portion OL311 may protrude from one end of the third body portion B3 in the first direction and extend in the second direction, and the first outer leg portion OL321 may protrude from one end of the fourth body portion B4 in the first direction and extend in the second direction.

[0155] The second outer leg portion OL312 may protrude from the other end of the third body portion B3 in the first direction and extend in the second direction, and the second outer leg portion OL322 may protrude from the other end of the fourth body portion B4 in the first direction and extend in the second direction. Each of the central leg portions CL31 and CL32 may protrude in the first direction between a corresponding one of the first outer leg portions OL311 and OL321 and a corresponding one of the second outer leg portions OL312 and OL322, and may extend in the second direction.

[0156] Meanwhile, the bobbin unit 120C may include a fifth body portion B2, a second upper protrusion UP2, and a first lower protrusion DP1.

[0157] Except for the shape and position of 2-1 and 2-2 through-holes TH21 and TH22 included in the fifth body portion B5 differing from those of the second body portion B2 according to the aforementioned embodiment, the fifth body portion B5 is identical to the second body portion B2, and therefore duplicative descriptions thereof will be omitted. The shape and position of the 2-1 and 2-2 through-holes TH21 and TH22 will be described later. In addition, the first lower protrusion DP1 is identical to the first lower protrusion DP1 of each of the aforementioned magnetic elements 100A and 100B, and therefore the same reference numerals are used and duplicative descriptions thereof will be omitted.

[0158] Unlike the aforementioned embodiments 100A and 100B, the bobbin unit 120C may not include a coil support portion 122. To this end, an upper coil 132 may be securely wound on the bobbin unit 120C so as not to descend in the direction of gravity.

[0159] The second upper protrusion UP2 may protrude from an upper end of the fifth body portion B5 in the second and third directions. Referring to FIG. 17B, the second upper protrusion UP2 may include a 2-1 upper protrusion UP21 and a 2-2 upper protrusion UP22. Each of the 2-1 upper protrusion UP21 and the 2-2 upper protrusion UP22 may include first and second outer upper protrusions OUP1 and OUP2 and an inner upper protrusion IUP.

[0160] In each of the 2-1 upper protrusions UP21 and the 2-2 upper protrusions UP22, the first and second outer upper protrusions OUP1 and OUP2 correspond to the parts disposed outside the core unit 110C, while the inner upper protrusion IUP corresponds to the part disposed inside the core unit 110C.

[0161] The 2-1 upper protrusion UP21 protrudes from the upper end of the fifth body portion B5 (e.g., UE1 shown in FIG. 17C) in at least one of the second direction or the third direction. The 2-1 upper protrusion UP21 is disposed between the first outer portion OL311 and the central leg portion CL31 of each of the first to third upper core segments 112C1, 112C2, and 112C3.

[0162] The 2-2 upper protrusion UP22 protrudes from the upper end of the fifth body portion B5 (e.g., UE2 shown in FIG. 17C) in at least one of the second direction or the third direction. The 2-2 upper protrusion UP22 is disposed between the second outer leg portion OL312 and the central leg portion CL31 of each of the first and second upper core segments 112C1, 112C2, and 112C3, and may be located on the opposite side of the 2-1 upper protrusion UP21 in the third direction. Consequently, the 2-1 and 2-2 upper protrusions UP21 and UP22 serve to support the plurality of upper core segments 112C1, 112C2, and 112C3.

[0163] Except for different shapes of the first and second outer upper protrusions OUP1 and OUP2 and different placement of the spacers USTR, USTL, LSTR, and LSTL, the 2-1 upper protrusion UP21 and the 2-2 upper protrusions UP22 are identical to the 1-1 upper protrusion UP11 and the 1-2 upper protrusion UP12, respectively. Therefore, duplicative descriptions of identical parts will be omitted, and only different parts will be described in detail.

[0164] For example, if each of the first and second thicknesses TK1 and TK2 of the 2-1 and 2-2 upper protrusions UP21 and UP22 in the first direction is less than 1 mm, the 2-1 and 2-2 upper protrusions may be susceptible to breakage. Therefore, each of the first and second thicknesses TK1 and TK2 may be 1 mm or more, but the embodiment is not limited thereto.

[0165] In addition, the width L2 of the 2-1 upper protrusion UP21 in the third direction and the width L1 of the 2-2 upper protrusion UP22 in the third direction may be the same.

[0166] The first through-hole TH1 of the fifth body portion B5 may have a width L3 in the third direction. That is, the width L3 may correspond to the shortest distance between the 2-1 upper protrusion UP21 and the 2-2 upper protrusion UP22 in the third direction. For example, the width L3 may be greater than the width L1 or L2, but the embodiment is not limited thereto.

[0167] In addition, the width of the 1-1 lower protrusion DP11 in the third direction and the width of the 1-2 lower protrusion DP12 in the third direction may be the same.

[0168] FIG. 18A is a plan view of a right corner of the magnetic element 100C shown in FIG. 12, FIG. 18B is a plan view of a left corner of the magnetic element 100C shown in FIG. 12 with the second outer upper protrusion OUP2 removed, FIG. 18C is a combined plan view of the coil unit 130B and the second core 114C, and FIG. 18D is a plan view of another embodiment of the right corner of the magnetic element 100C shown in FIG. 12. In FIG. 18B, an outer upper protrusion CV4 is shown as a dotted line to aid in understanding the placement thereof relative to the upper coil 132.

[0169] The first and second outer upper protrusions OUP1 and OUP2 protrude from the inner upper protrusion IUP in the second direction intersecting the first direction and are located outside the core unit 110C. The inner upper protrusion IUP protrudes from the fifth body portion B5 in the third direction and is located in the core unit 110C.

[0170] Referring to FIG. 17B, each of the first outer upper protrusion OUP1 (hereinafter referred to as 'CV1') of the 2-1 upper protrusion UP21 and the first outer upper protrusion OUP2 (hereinafter referred to as 'CV2') of the 2-2 upper protrusion UP22 may have a fan-shaped planar configuration with a central angle of 90°.

[0171] In addition, each of the second outer upper protrusion OUP2 (hereinafter referred to as 'CV3') of the 2-1 upper protrusion UP21 and the second outer upper protrusion OUP2 (hereinafter referred to as 'CV4') of the 2-2 upper protrusion UP22 may also have a fan-shaped planar configuration with a central angle of 90°.

[0172] Each of the outer upper protrusions CV1 to CV4 may include first and second portions P1 and P2. For example, referring to FIG. 18B, the first portion P1 of the outer upper protrusion CV4 corresponds to the part overlapping the coil unit 130B in the first direction, and the second portion P2 thereof corresponds to the part extending horizontally from the first portion P1.

[0173] It is desirable for the second portion P2 to protrude as little as possible from the first portion P1. For example, when the coil unit 130B includes a plurality of coils CO1, CO2, CO3, and CO4, the second portion P2 may extend at least as far as half the diameter Φ of the outermost coil CO4 included in the coil unit 130B. If the size d of the second portion P2 is less than half the diameter Φ, the upper coil 132 may escape when winding the coil unit 130B onto the bobbin unit 120C.

[0174] The coil unit 130B may include an upper coil 132 and a lower coil 134 disposed on the bobbin unit 120C. The description of the coil unit 130A shown in FIG. 6 may apply to the coil unit 130B of the magnetic element 100C according to the yet another embodiment, and therefore duplicative descriptions thereof will be omitted. That is, in the magnetic element 100C according to the yet another embodiment, the depiction of the first to fourth wires W1, W2, W3, and W4 described in the embodiments 100A and 100B is omitted; however, wires W1 to W4 may be connected to the coil 130B of the magnetic element 100C, as in the aforementioned embodiments 100A and 100B.

[0175] The outermost coil (e.g., CO4) of the coil unit 130B and the outermost parts of the outer upper protrusions CV1, CV2, CV3, and CV4 have the same planar shape, i.e., a round planar shape.

[0176] Referring to FIG. 18C, the coil unit 130B may include an inner portion CIP disposed in the core unit 110C and outer portions COP1 and COP2 disposed outside the core unit 110C. That is, the part of the coil unit 130B disposed in the core unit 110C is defined as the inner portion CIP, and the part disposed outside the core unit 110C is defined as the outer portions COP1 and COP2.

[0177] Each of the outer portions COP1 and COP2 may include a central portion CCP and peripheral portions CPP1 and CPP2.

[0178] The first and second outer upper protrusions OUP1 and OUP2 are disposed on the outer portions COP1 and COP2, and the inner upper protrusion IUP is disposed on the inner portion CIP.

[0179] According to an embodiment, the central portion CCP corresponds to the part of each of the outer portions COP1 and COP2 having a quadrangular planar shape, and the peripheral portions CPP1 and CPP2 correspond to the parts of each of the outer portions COP1 and COP2 excluding the central portion CCP and may be disposed on the periphery of the central portion CCP.

[0180] According to another embodiment, the central portion CCP corresponds to the part of each of the outer portions COP1 and COP2 overlapping a central leg portion (e.g. CL32 (CL321, CL322, and CL323) shown in FIG. 18C) of the core unit 110C (e.g. the second core 114C shown in FIG. 18C) in the second direction, and the peripheral portions CPP1 and CPP2 may correspond to the parts of each of the outer portions COP1 and COP2 excluding the central portion CCP.

[0181] Each of the peripheral portions CPP1 and CPP2 may have a fan-shaped planar configuration with a central angle of 90° and disposed on the periphery of the central portion CCP. At this time, the outer upper protrusions CV1, CV2, CV3, and CV4 may be disposed on the peripheral portions CPP1 and CPP2.

[0182] Each of the outer upper protrusions CV1, CV2, CV3, and CV4 may include first, second, and third surfaces SP1, SP2, and SP3.

[0183] As shown in FIG. 18A, the first surface SP1 is a surface adjacent to the central portion CCP and may overlap boundaries BD11, BD12, BD21, and BD22 between the central portion CCP and the peripheral portions CPP1 and CPP2 shown in FIG. 18C in the first direction. The second surface SP2 may overlap a boundary BD2 between the inner portion CIP and the peripheral portions CPP1 and CPP2 in the first direction. The third surface SP3 is disposed between the first surface SP1 and the second surface SP2. According to the embodiment, the third surface SP3 has a curved planar shape.

[0184] According to another embodiment, the first surface SP1 of each of the outer upper protrusions CV1, CV2, CV3, and CV4 may be spaced apart from the boundaries BD11, BD12, BD21, and BD22 by a predetermined distance in the third direction toward the outside of the magnetic element 100C. That is, the first surface SP1 may be spaced apart from the central portion CCP by a predetermined distance in the third direction. For example, as shown in FIG. 18D, the outer upper protrusion CV1 may be spaced apart from the boundary BD11 by a first predetermined distance PY1 in a +z axis direction, the outer upper protrusion CV2 may be spaced apart from the boundary BD12 by a second predetermined distance in a -z axis direction, the outer upper protrusion CV3 may be spaced apart from the boundary BD21 by a third predetermined distance in the +z axis direction, and the outer upper protrusion CV4 may be spaced apart from the boundary BD22 by a fourth predetermined distance in the -z axis direction.

[0185] The first and second predetermined distances may be determined such that at least 50% of the outer portion COP1 is not covered by the outer upper protrusions CV1 and CV2 and is exposed on the plane. In addition, the third and fourth predetermined distances may be determined such that at least 50% of the outer portion COP2 is not covered by the outer upper protrusions CV3 and CV4 and is exposed on the plane. Consequently, a large part of the coil unit 130B may be exposed to an air flow path for cooling the magnetic element 100C, thereby improving heat dissipation performance of the magnetic element 100C.

[0186] FIG. 19A is a plan view of a magnetic element 100D according to a further embodiment, and FIG. 19B is an enlarged view of part 'A' of FIG. 19A.

[0187] Except for different planar shapes of outer upper protrusions CV5 to CV8, the magnetic element 100D according to the further embodiment is identical to the magnetic element 100C according to the yet another embodiment. Therefore, identical parts are denoted by the same reference numerals, and duplicative descriptions thereof will be omitted.

[0188] The outer upper protrusions CV5 to CV8 perform the same function as the outer upper protrusions CV1 to CV4, respectively. First and second upper core segments 112C1 and 112C2 are spaced apart from each other by a predetermined distance YG3 in the second direction, and second and third upper core segments 112C2 and 112C3 are spaced apart from each other by a predetermined distance YG4 in the second direction, wherein the distances YG3 and YG4 may be the same or may differ depending on the case.

[0189] The outer upper protrusion CV8 will be described with reference to FIG. 19B; however, the description of the outer upper protrusion CV8 may also apply to the other outer upper protrusions CV5, CV6, and CV7.

[0190] First, the outer upper protrusion CV8 may have a planar shape that does not extend beyond the outermost one CO1 of the plurality of coils 132 (CO1, CO2, CO3, and CO4) in the second direction.

[0191] The outer upper protrusion CV8 may include fourth, fifth, and sixth surfaces SP4, SP5, and SP6.

[0192] The fourth surface SP4 is a part near the central portion CCP of the coil unit 130B, the fifth surface SP5 is a part of the outer upper protrusion CV8 chamfered (or filleted) as the outermost surface in the third direction, and the sixth surface SP6 is a surface between the fourth surface SP4 and the fifth surface SP5 and corresponds to the outermost surface of the outer upper protrusion CV8 in the second direction.

[0193] According to the embodiment, the fifth surface SP5 may be disposed so as to cover at least 50% of the diameter of the outermost coil CO1 and does not protrude farther than the outermost side of the core unit 110C in the third direction (that is, the -z axis direction). In addition, the sixth surface SP6 may be disposed so as not to extend beyond an outer line of the outermost coil CO1 in the second direction to ensure smooth air flow.

[0194] Furthermore, in the same manner as the outer upper protrusion CV4, the fourth surface SP4 of the outer upper protrusion CV8 may also be spaced apart from the boundary BD22 by a predetermined distance PY2 in the third direction. In this case, the predetermined distance PY2 may be determined such that at least 50% of the outer portion COP2 is not covered by the outer upper protrusions CV7 and CV8 and is exposed on the plane.

[0195] Meanwhile, the magnetic element 100C according to the embodiment may include spacers USTR, USTL, LSTR, and LSTL.

[0196] FIGs. 20A and 20B are, respectively, a side view and a front view of the magnetic element 100C shown in FIG. 12.

[0197] Referring to FIGS. 17A, 17B, and 20A, the bobbin unit 100C may further include upper spacers USTR and USTL and lower spacers LSTR and LSTL.

[0198] The upper spacers USTR and USTL protrudes between the plurality of upper core segments 112C1, 112C2, and 112C3 from the inner upper protrusion IUP in the third direction to maintain a uniform distance between the plurality of upper core segments 112C1, 112C2, and 112C3.

[0199] The lower spacers LSTR and LSTL protrude between the plurality of lower core segments 114C1, 114C2, and 114C3 from the first lower protrusion DP1 (DP11 and DP12) in the third direction to maintain a uniform distance between the plurality of lower core segments 114C1, 114C2, and 114C3.

[0200] The number of each of the upper spacers USTR and USTRL is one less than the number of the plurality of upper core segments 112C1, 112C2, and 112C3, and the number of each of the lower spacers LSTR and LSTRL may be one less than the number of the plurality of lower core segments 114C1, 114C2, and 114C3.

[0201] The spacers ST1, ST2, and ST3 of the magnetic element 100B according to the other embodiment described above protrude in the first direction, whereas in the magnetic element 100C according to the yet another embodiment, at least one of the upper spacers USTR and USTL or the lower spacers LSTR and LSTL may protrude in the third direction.

[0202] In addition, the upper spacers USTR and USTL and the lower spacers LSTR and LSTL may be disposed so as to overlap each other in the first direction. Therefore, the gap YG1 by which the upper core segments 112C1, 112C2, and 112C3 are spaced apart from each other by the upper spacers USTR and USTL and the gap YG2 by which the lower core segments 114C1, 114C2, and 114C3 are spaced apart from each other by the lower spacers LSTR and LSTL may communicate with each other, whereby heat generated in the magnetic core 100C may be discharged through the second through-hole TH2 and smoothly vented to the outside via the gaps YG1 and YG2. To this end, the second through-hole TH2 may communicate with the gaps YG1 and YG2.

[0203] According to the embodiment, referring to FIG. 15, the width YW of each of the upper spacers USTR and USTL or the lower spacers LSTR and LSTL in the second direction may be determined so as to satisfy Equation 3 below. N − 1 × YW ≤ THV

[0204] Here, N indicates the number of divided segments of the first core 112C or the second core 114C, YW indicates the width of the upper spacers USTR and USTL or the lower spacers LSTR and LSTL in the second direction, and THV indicates the distance between the plurality of upper core segments 112C1, 112C2, and 112C3 or the plurality of lower core segments 114C1, 114C2, and 114C3 in the second direction for maintaining the critical reduction amount of inductance that the magnetic element 100C must have to preserve the inductance at the maximum value.

[0205] For example, the width of the upper spacers USTR and USTL in the second direction and the width of the lower spacers LSTR and LSTL in the second direction may be the same. Setting THV to 4 mm or more for heat dissipation of the magnetic element 100C may reduce inductance by 15% or more. Therefore, THV may be determined to be 4 mm, but the embodiment is not limited to a specific value for THV.

[0206] Meanwhile, as the second through-hole TH2 is formed in the bobbin 120A of each of the magnetic elements 100A and 100B according to the aforementioned embodiments has a therein, the second through-hole TH2 may also be formed in the bobbin 120C of each of the magnetic element 100C and 100D in the other embodiments. Hereinafter, the description related to the second through-hole TH2 of the magnetic element 100C may also apply to the magnetic elements 100A, 100B, and 100D according to the aforementioned embodiments.

[0207] FIG. 21A is a combined perspective view of the bobbin 120C and the core unit 110C of the magnetic element 100C shown in FIG. 12, and FIG. 21B is a perspective view of the magnetic element 100C shown in FIG. 21A with the first core 112C removed.

[0208] According to another embodiment, the bobbin 120C may further include a second through-hole TH2 formed through the fifth body portion B5 in a direction intersecting the first direction (e.g., at least one of the second direction or the third direction).

[0209] In the same manner as the second body portion B2, the fifth body portion B5 may include first to fourth side portions S1 to S4. Referring to FIG. 17B, the first and second side portions S1 and S2 may be opposite each other in the third direction intersecting the first direction, and the third and fourth side portions S3 and S4 may be opposite each other in the second direction and disposed between the first and second side portions S1 and S2.

[0210] The second through-hole TH2 may include a plurality of second through-holes TH2 formed in at least one of the first to fourth side sections S1 to S4. According to the embodiment, the plurality of second through-holes TH2 may be located on the same horizontal line.

[0211] For example, the second through-hole TH2 may include a 2-1 through-hole TH21 formed in the first and second side portions S1 and S2 of the fifth body portion B5 and a 2-2 through-hole TH22 formed in the third and fourth side portions S3 and S4 of the fifth body portion B5. Second through-holes TH2 of the same shape and size or second through-holes TH2 of different shapes and size may be formed in the first to fourth side portions S1, S2, S3, and S4 of the fifth body portion B5, and the embodiment is not limited to specific shapes and sizes of the second through-holes TH2.

[0212] For example, the 2-1 and 2-2 through-holes TH21 and TH22 may have the same quadrangular shape, as shown, but the sizes thereof may differ.

[0213] Before describing the second through-hole TH2 in detail, the core unit 110C shown in FIG. 12 will be briefly described with reference to the accompanying drawings as follows.

[0214] FIG. 22 is a combined perspective view of the core unit 110C shown in FIG. 13.

[0215] As described above, the central leg portion CL31 of the first core 112C and the central leg portion CL32 of the second core 114C may be spaced apart from each other in the first direction to form a gap XG. For example, the inductance of the magnetic element 100C may be adjusted using the size of the gap XG. The larger the gap XG, the greater the decrease in the inductance. For example, the distance of the gap XG in the first direction may be 10 µm to 100 µm, but the embodiment is not necessarily limited thereto.

[0216] According to the embodiment, the size of the second through-hole TH2 may be proportional to the size of the gap XG. This is because, as the size of the gap XG increases, the amount of generated heat increases, necessitating rapid heat dissipation to the outside through the second through-hole TH2.

[0217] In addition, according to the embodiment, the length a1 or a2 of the second through-hole TH2 in the first direction may be greater than or equal to the length of the gap XG in the first direction.

[0218] In addition, according to the embodiment, the space SP between the upper coil 132 and the lower coil 134 shown in FIGs. 6, 20A, and 20B may communicate with the second through-hole TH2.

[0219] Furthermore, in order to ensure that heat in the magnetic element 100C is discharged through the second through-hole TH2 and the heat discharged through the second through-hole TH2 is effectively discharged to the outside, the second through-hole TH2 may overlap the gaps YG1 and YG2 in the third direction.

[0220] The bobbin unit 120C serves to secure the winding of the coil unit 130B and to insulate the coil unit 130B from the core unit 110C. Considering this, the coil unit 130B may be wound avoiding the place at which the central leg portions CL31 and CL32 are exposed due to the second through-hole TH2. If the central leg portions CL31 and CL32 are exposed through the second through-hole TH2, i.e., if at least a part of each of the central leg portions CL31 and CL32 overlaps the second through-hole TH2 in the horizontal direction, the upper coil 132 may be disposed above the second through-hole TH2 and the lower coil 134 may be disposed under the second through-hole TH2.

[0221] If the bobbin unit 120C is not disposed between the coil unit 130B and the core unit 110C, the magnetic element may become vulnerable to withstand voltage. Therefore, the coil unit 130B may be wound on the bobbin unit 120C such that the insulation creepage distance between the coil unit 130B and the core unit 110C is 5.5 mm or more.

[0222] In addition, the height of the second through-hole TH2 in the first direction may be determined so as to satisfy Equation 4 below. h × i − g × 1.1 ≥ a

[0223] Here, referring to FIGs. 6 and 21A, h indicates the height of the space SS1 or SS2 in which the coil unit 130A or 130B is wound between the central leg portion and the first or second outer leg portion in the first direction, i indicates the width of the space SS1 or SS2 in the third direction, g indicates the total sectional area SA of the coil present in the space SS1 or SS2, and a indicates the height a1 of the 2-1 through-hole TH21 in the first direction or the height a2 of the 2-2 through-hole TH22 in the first direction.

[0224] Furthermore, in order to dissipate heat generated in the central leg portions CL31 and CL32, the heights a1 and a2 of the second through-hole TH2 in the first direction must be greater than the length of the gap XG in the first direction, i.e., the distance by which the central leg portions are spaced apart from each other in the first direction. However, as the heights a1 and a2 of the second through-hole TH2 increase, the area in which the coil unit 130B can be wound may decrease. Considering this, the heights a1 and a2 of the second through-hole TH2 in the first direction may be 10% or more of the length of the gap XG in the first direction, but the embodiment is not limited thereto.

[0225] Furthermore, in order to facilitate heat dissipation, the total area of the second through-hole TH2 may be 50% or more of the area of the gap XG. That is, the size of the second through-hole TH2 may be determined considering Equation 5 below. a × b × n ≥ c × d 2 × 0.5

[0226] Here, a indicates the lengths a1 and a2 of the second through-hole TH2 (TH21 and TH22) in the first direction, b indicates the widths b1 and b2 of the second through-hole TH2 (TH21 and TH22) in the horizontal direction, n indicates the total number of second through-holes TH2 (TH21 and TH22), c indicates the length of the gap XG in the first direction, and d2 indicates the length of the gap XG in the third direction.

[0227] In addition, the total area of the second through-hole TH2 may be determined so as to satisfy Equation 6 below. a × b × n ≤ a × e + a × f

[0228] Here, e indicates the length of the fifth body portion B5 in the third direction, and f indicates the length of the fifth body portion B5 in the second direction. For example, the left side of Equation 6 may be 90% of the right side. This is because, if the left side of Equation 6 (the total area of the second through-hole TH2) exceeds 90% of the right side, there is a risk of the bobbin breaking.

[0229] In addition, as the horizontal widths b1 and b2 of the second through-hole TH2 (TH21 and TH22) increase, heat dissipation performance increases, but the widths b1 and b2 may be determined to prevent breakage of the bobbin unit 120C. This is because, if the widths b1 and b2 increase, the bobbin unit 120C may break.

[0230] In addition, according to the embodiment, at least one of the first gap YG1 between the plurality of upper core segments 112C1, 112C2, and 112C3 formed by the upper spacers USTR and USTL or the second gap YG2 between the plurality of lower core segments 114C1, 114C2, and 114C3 formed by the lower spacers LSTR and LSTL may overlap and communicate with the second through-hole TH2 in the third direction.

[0231] When air flows in the -y axis direction due to a fan for dissipating heat from the magnetic element, if the second through-hole TH2 as in the embodiment is not formed, there is no gap in the magnetic element, whereby air flows only outside the magnetic element, making it difficult to cool the interior of the magnetic element.

[0232] Furthermore, this phenomenon may be exacerbated if the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 are not spaced apart from each other but are attached to each other.

[0233] In contrast, according to the yet another embodiment described above, when air flows in the -y axis direction due to a fan for dissipating heat from the magnetic element 100C, heat generated from the central leg portions CL31 and CL32 of the core unit 110C due to fringing flux and heat of the coil 130B may be discharged outside the bobbin unit 120C through the second through-hole TH2. Particularly, according to the yet another embodiment, the heat discharged outside the bobbin unit 120C may be discharged to the outside through the first and second gaps YG1 and YG2 of the core unit 110C. Therefore, the magnetic element 100C according to the embodiment may be usefully employed for high-power modules generating significant heat, such as a 40kW-class fast-charging module. Furthermore, if the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 are not spaced apart from each other but are attached to each other, inductance fluctuates, whereby constant inductance is not guaranteed. Furthermore, if the upper spacers USTR and USTL or the lower spacers LSTR and LSTL are not provided, vibration between the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 may easily damage the core unit 110C.

[0234] However, according to the embodiment, the upper spacers USTR and USTL or the lower spacers LSTR and LSTL are disposed such that the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3 are spaced apart from each other, whereby damage to the core unit 110C may be prevented while constant inductance is guaranteed. In addition, the upper spacers USTR and USTL or the lower spacers LSTR and LSTL may increase the surface area exposed to air contact in the plurality of upper core segments 112C1, 112C2, and 112C3 and the plurality of lower core segments 114C1, 114C2, and 114C3, thereby further improving the heat dissipation effect. FIGs. 23A to 23C are plan views illustrating various outer upper protrusions of the magnetic element according to the embodiment.

[0235] The magnetic element shown in FIGs. 23A and 23C is identical to the magnetic element shown in FIG. 18A, except for different shapes of outer upper protrusions 40 and 44, and therefore duplicative descriptions thereof will be omitted. In addition, FIG. 23B corresponds to the magnetic element 100D shown in FIG. 19A, and therefore duplicative descriptions of identical parts will be omitted.

[0236] As described above, the outer upper protrusions 40, 44, CV1, CV2, CV3, CV4, CV5, CV6, CV7, and CV8 serve to cover the peripheral portions CPP1 and CPP2 of the coil unit 130B to prevent the peripheral portions CPP1 and CPP2 from escaping. As such, the outer upper protrusions 40, 44, CV1, CV2, CV3, CV4, CV5, CV6, CV7, and CV8 serve as anti-disengagement pieces that prevent disengagement of the coil unit 130B wound on the bobbin unit 120C. However, while the outer upper protrusions covering the outer portions COP1 and COP2 including the peripheral portions CPP1 and CPP2 and the central portion CCP of the coil unit provide the advantage of preventing disengagement of the coil unit, this may make it difficult for the coil unit to contact air, hindering effective heat dissipation from the coil unit.

[0237] Therefore, as shown in FIGs. 23A to 23C, the outer upper protrusions 40, CV5, 44, CV1, CV2, CV3, and CV4 cover at least a part of each of the peripheral portions CPP1 and CPP2 without covering the central portion CCP of the coil unit 130B, thereby minimizing the size of the outer upper protrusions 40, CV5, 44, CV1, CV2, CV3, and CV4 or determining the shape and position thereof.

[0238] Furthermore, as shown in FIGs. 23A and 23C, if outer corners 40P and 44P of the outer upper protrusions 40 and 44 are angularly formed, the coil may be damaged during winding of the coil. Therefore, as shown in FIG. 18A or 23B, the outer surfaces SP3 and SP5 of the outer upper protrusions CV1 and CV5 can be rounded to prevent coil damage during winding of the coil unit 130B.

[0239] FIG. 24A is a lower assembled perspective view of the magnetic element shown in FIG. 23A, and FIG. 24B is a lower assembled perspective view of the magnetic element 100D shown in FIGs. 19A and 23B.

[0240] Furthermore, in FIGs. 18A, 23A to 23C, 24A, and 24B, when air is introduced in the -y axis direction by the fan, the air flows in the directions indicated by the arrows. At this time, in FIGs. 23A, 23C, and 24A, the angular shape of each of the outer upper protrusions 40 and 44 may significantly impede the flow of air. However, as shown in FIGs. 18A, 23B, and 24B, if the outer surface of each of the outer upper protrusions CV1 and CV5 is curved, the air flow may be mitigated compared to FIGs. 23A, 23C, and 24A. Particularly, as shown in FIG. 18A, when the outer upper protrusion CV1 has a planar shape like a shark fin, the air flow becomes ideal, improving heat dissipation performance.

[0241] As described above, in the magnetic element 100C according to the yet another embodiment, outside air may flow smoothly into the central leg portions CL31 and CL32, thereby reducing the temperature of the magnetic element 100C by 10°C or more.

[0242] Furthermore, if the bobbin unit 120C is not disposed, sharp parts CP1A and CP1B of the corners of the core unit 114C may easily damage the coil unit 130B, whereby the core unit 114C and the coil unit 130B may be short circuited instead of being electrically insulated from each other, causing drive problems. In order to prevent this, according to the embodiment, the coil unit 130B is wound on the bobbin unit 120C, and then the core unit 110C is assembled in the bobbin unit 120C.

[0243] Hereinafter, with reference to FIG. 13, an assembly process of the magnetic element 100C according to the yet another embodiment will be described with reference to FIG. 13.

[0244] The coil unit 130B is wound so as to wrap around the outside of the fifth body portion B5 of the bobbin unit 120C. The coil unit 130B may be wound so as to correspond to the spaces between the outer leg portions OL311, OL312, OL321, and OL322 and the central leg portions CL31 and CL32 of each of the first core 112C and the second core 114C.

[0245] After the coil unit 130B is wound on the fifth body portion B5 of the bobbin unit 120C, the central leg portion CL32 of the second core 114C is inserted into the first through-hole TH1 formed in the fifth body portion B5 of the bobbin unit 120C. At this time, the coil unit 130B wound on the fifth body portion B5 of the bobbin unit 120C is inserted into the space between the central leg portion CL32 and each of the outer leg portions OL321 and OL322 of the second core 114C. The first core 112C may also be coupled to an upper part of the fifth body portion B5 of the bobbin unit 120C in the same manner as the second core 114C.

[0246] Although the above has been described based on the embodiments, these are merely illustrative and do not limit the present disclosure, and those skilled in the art will recognize that various modifications and applications not illustrated herein are possible without departing from the essential features of the present embodiments. For example, each of the components specifically shown in the embodiments may be practiced with variations. The differences with respect to such variations and applications are to be construed as being within the scope of the present disclosure as defined by the appended claims.[Mode for Disclosure]

[0247] The mode for disclosure has been sufficiently described in the aforementioned "Best Mode."[Industrial Applicability]

[0248] A magnetic element according to an embodiment may be used in instrument transformers, AC control panels, DC converters (DC-DC converters), step-up converters, step-down converters, etc.

Examples

Embodiment Construction

[0035]The present disclosure may be changed in various manners and may have various embodiments. Specific embodiments of the present disclosure will be described with reference to the drawings. However, the present disclosure is not limited to the specific embodiments, and it should be understood that the present disclosure includes all modifications, equivalents, or substitutions included in the idea and technical scope of the present disclosure.

[0036]Although terms including ordinal numbers, such as "first" and "second," may be used herein to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another component. For example, without departing from the scope of the present disclosure, a second component may be named a first component, and similarly, a first component may be named a second component. The term "and / or" includes any combination of a plurality of related listed items or any one ...

Claims

1. A magnetic element, comprising: a core unit including a first core and a second core disposed opposite the first core in a first direction; a bobbin unit at least partially disposed in the core unit; and a coil unit including an upper coil and a lower coil disposed on the bobbin unit, wherein the upper coil and the lower coil are disposed spaced apart from each other in the first direction.

2. The magnetic element according to claim 1, wherein each of the first and second cores includes: a first body portion; a first outer leg portion protruding from one end of the first body portion in the first direction and extending in a second direction intersecting the first direction; a second outer leg portion protruding from the other end of the first body portion in the first direction and extending in the second direction; and a central leg portion protruding between the first outer leg portion and the second outer leg portion in the first direction and extending in the second direction.

3. The magnetic element according to claim 2, wherein at least a part of the upper coil is disposed between each of the first and second outer leg portions and the central leg portion of the first core, and at least a part of the lower coil is disposed between each of the first and second outer leg portions and the central leg portion of the second core.

4. The magnetic element according to claim 2, wherein the bobbin unit includes: a second body portion on which the upper coil and the lower coil are disposed spaced apart from each other in the first direction; a first upper protrusion protruding from an upper end of the second body portion in a third direction intersecting each of the first and second directions; and a first lower protrusion protruding from a lower end of the second body portion in the third direction.

5. The magnetic element according to claim 4, wherein the first upper protrusion includes: a 1-1 upper protrusion disposed between the first outer leg portion and the central leg portion of the first core; and a 1-2 upper protrusion disposed between the second outer leg portion and the central leg portion of the first core, the 1-2 upper protrusion being located on an opposite side of the 1-1 upper protrusion in the third direction.

6. The magnetic element according to claim 4, wherein the first lower protrusion includes: a 1-1 lower protrusion disposed between the first outer leg portion and the central leg portion of the second core; and a 1-2 lower protrusion disposed between the second outer leg portion and the central leg portion of the second core, the 1-2 lower protrusion being located on an opposite side of the 1-1 lower protrusion in the third direction.

7. The magnetic element according to claim 4, wherein the bobbin unit further includes a coil support portion protruding from the second body portion between the first upper protrusion and the first lower protrusion in a horizontal direction, the coil support portion being configured to support the upper coil.

8. The magnetic element according to claim 4, wherein the first upper protrusion and the first lower protrusion overlap each other in the first direction.

9. The magnetic element according to claim 4, wherein the second body portion includes a first through-hole formed through the second body portion in the first direction, and the central leg portion of each of the first and second cores is inserted into and disposed in the first through-hole.

10. The magnetic element according to claim 9, wherein the first through-hole has a first length in the first direction, the central leg portion of the first core has a second length in the first direction, the central leg portion of the second core has a third length in the first direction, and a sum of the second length and the third length is less than the first length.

Images