Magnetic Component and Manufacturing Method

Abstract

Provided are a novel magnetic component and a method of manufacturing the magnetic component. **Solution**: An improved magnetic component is provided. The component includes a magnetic core (MCR) and a coil (CL) having a winding (W) wound around the magnetic core. The magnetic component further has a main magnetic flux path (MFP) within the magnetic core (MCR) and a stray magnetic flux region (STA) outside the magnetic core. The stray magnetic flux path or region (STA) is at least partially embedded in or induced by a first material (M1).

Description

Technical Field

[0001] The present invention relates to magnetic components having improved properties and a method of manufacturing such components.

Background Art

[0002] Magnetic components such as magnetic coils should have ideal magnetic and electromagnetic properties. However, physical realization exhibits deviations from the ideal properties.

[0003] From German Patent Application Publication No. 10 2017 114 900, a multiphase coupled inductor is known. From U.S. Patent No. 10,163,563, a component having a coil fixed in a cavity and containing additional substances is known. From U.S. Patent Application Publication No. 2020 / 0286667, a magnetic component structure having a filler is known.

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, there is a need to obtain magnetic components having improved properties. Specifically, there is a need to obtain magnetic components having improved magnetic, thermal, and insulation properties.

Means for Solving the Problems

[0005] For that purpose, a magnetic component according to independent claim 1 is provided. The dependent claims provide preferred embodiments and corresponding methods for manufacturing such components.

[0006] The magnetic component includes a magnetic core and a coil having a winding wound around the magnetic core. The magnetic component further has a main magnetic flux path in the magnetic core and a stray magnetic region outside the magnetic core. However, the stray magnetic flux region is at least partially embedded in or induced by a first material.

[0007] The magnetic component may be a coupled inductor having two or more inductive segments magnetically or electromagnetically coupled to each other.

[0008] The magnetic component is based on the concept that in a coupled inductor, especially during operation, magnetic flux lines are substantially contained within an object, for example within a solid magnetic structure, for example within a magnetic core.

[0009] In addition, it has been found beneficial that the magnetic flux outside the magnetic structure, for example stray flux, is still contained within a predefined material having predefined magnetic and / or thermodynamic properties.

[0010] Thus, the magnetic component is provided such that the magnetic flux outside the magnetic core is at least partially contained within a material for a specific application, i.e. a first material, for example a magnetic resin.

[0011] At this time, the stray flux can be concentrated in a material for a specific application, i.e. a first material, having correspondingly selected magnetic, electromagnetic and thermodynamic properties such as permeability, conductivity and thermal conductivity.

[0012] Furthermore, the first material, for example a magnetic resin, can also contribute to conducting unwanted heat due to the external environment of the magnetically active region of the component, for example the outer surface, the coolant in which the component is arranged or an external thermal bridge, for example an aluminum object. In addition, the first material may be used in a suitable electrical insulation system.

[0013] In the magnetic component, it is also possible that the first material is a thermally conductive filler or a potting material.

[0014] It is also possible that the magnetic component is a coupled inductor having two or more inductive segments magnetically or electromagnetically coupled to each other.

[0015] In the magnetic component, it is also possible that the first material has a magnetic permeability μ_1 such that 1.5 ≦ μ_1 ≦ 26.

[0016] In the magnetic component, it is also possible that the magnetic core has a magnetic permeability μ_2 such that 26 ≦ μ_2 ≦ 27000.

[0017] In the magnetic component, it is also possible that the first material has a thermal conductivity of 0.5 W / mK or more.

[0018] In the magnetic component, it is also possible that the first material has an electrical resistivity r such that r ≧ 10 kV / mm.

[0019] In the magnetic component, it is also possible that the magnetic core includes an upper magnetic core part and a lower magnetic core part. Further, the upper magnetic core part and the lower magnetic core part form a casing having a front opening and a rear opening.

[0020] However, it is also possible that the number of components of the magnetic core is more than two.

[0021] Furthermore, it is also possible that the magnetic core is provided as an integral part. Thus, the number of components of the magnetic core may be one.

[0022] In the magnetic component, it is also possible that the coil is mounted on the casing.

[0023] In the magnetic component, it is also possible that the coil includes a first terminal connection part and a second terminal connection part. Further, the first terminal connection part and the second terminal connection part extend outward from the front surface or the front opening of the component.

[0024] In the magnetic component, it is also possible that the first material is disposed around the coil and / or the magnetic core.

[0025] In a magnetic component, it is also possible that the lower magnetic core part or the upper magnetic core part includes a central column for at least partially mounting a coil. Further, the central column extends upward from the mounting plane of the lower magnetic core part and is offset from the center of the mounting plane to the front opening.

[0026] Furthermore, in a magnetic component, it is also possible that the magnetic core is integrally constructed and includes a central column for at least partially mounting a coil. At this time, the central column extends upward from the mounting plane of the magnetic core and is offset from the center of the mounting plane to the front opening.

[0027] In a magnetic component, it is also possible that the surface of the first material is flush with the rear opening.

[0028] In a magnetic component, it is also possible that a part of the first material protrudes from the rear opening.

[0029] The magnetic component may further include a bobbin mounted on the lower magnetic core part, and the coil may be wound around the bobbin.

[0030] In a magnetic component, it is also possible that the bobbin includes or is made of a plastic material.

[0031] The magnetic component may further include insulating paper and / or an insulating film disposed between the coil and the upper magnetic core part.

[0032] The magnetic component may further include a thermal conductive interface material between the first material and the upper magnetic core part and / or between the first material and the lower magnetic core part. The thermal conductive interface material has a hardness equal to or lower than the hardness of the first material, or the upper magnetic core part, or the lower magnetic core part.

[0033] In a magnetic component, it is also possible that the first material at least partially fills the component casing from the rear opening to the front opening.

[0034] In the magnetic component, it is also possible that the first material at least partially fills the casing from the mounting plane of the lower magnetic core part to the upper magnetic core part.

[0035] In the magnetic component, it is also possible that the magnetic core, the lower magnetic core part and / or the upper magnetic core part comprise or consist of a material selected from Fe-Si alloys, Fe-Ni alloys, MnZn or MnZn-based alloys, NiZn or NiZn-based alloys.

[0036] In the magnetic component, it is also possible that the first material comprises or consists of a material selected from thermosetting phenolic resins, thermoplastic polyethylene terephthalate (PET), polyamide (PA), polyphenylene sulfide (PPS), and polyether ether ketone (PEEK), PUR (polyurethane), epoxy, and silicone-based resins.

[0037] In the magnetic component, it is also possible that the front opening and the rear opening are arranged on opposite sides of each other in two parallel and opposite directions of the expansion stress in order to reduce the expansion stress acting on the upper magnetic core part and the lower magnetic core part.

[0038] In the magnetic component, it is also possible that the first material does not completely seal the outer surfaces of the upper magnetic core part and the lower magnetic core part.

[0039] For example, the method of manufacturing the above magnetic component is preparing a mold with a coil mounted thereon; potting the mold with a thermally conductive material to form the first material; sealing at least a part of the coil; releasing the first material and the coil from the mold; combining the first material with the magnetic core and includes.

[0040] The mold includes a lower magnetic core part, The step of combining the first material with the magnetic core includes combining the lower magnetic core part with the upper magnetic core part, The first material can be arranged or accommodated between the upper magnetic core part and the lower magnetic core part is also possible.

[0041] The method is the step of attaching a bobbin to the lower magnetic core part, the step of winding a coil around the bobbin, the step of sealing a part of the coil in the bobbin and the lower magnetic core part with the first material can also be further included.

[0042] In the method, the mold includes a lower magnetic core part and an upper magnetic core part, The step of combining the first material with the magnetic core includes combining the lower magnetic core part, the upper magnetic core part and the first material, and the first material can be arranged or accommodated between the upper magnetic core part and the lower magnetic core part is also possible.

[0043] The method can also further include the step of arranging a thermal conductive interface material between the coil and the first material.

[0044] The method is the step of preparing a mold including an upper magnetic core part and a lower magnetic core part and a coil attached to the mold, the step of potting the mold with a thermal conductive material to form a thermal conductive filler, the step of sealing at least a part of the coil can also be further included.

[0045] Therefore, due to the above characteristics, the first material, such as resin, is used to generate a specified magnetic path or for shielding purposes.

[0046] Furthermore, a first material, such as a resin, is used to thermally fix a cast part, such as a bonding inductor, to its interface, such as an aluminum housing.

[0047] Furthermore, a first material, such as a resin, enables electrical insulation between, for example, a bonded coil segment and its environment, such as a housing, such as an aluminum housing.

[0048] The basic operating principle and details of the preferred embodiments are shown in the schematic attached drawings.

[0049] In the drawings, it is as follows.

Brief Description of the Drawings

[0050]

Figure 1

Figure 2

Mode for Carrying Out the Invention

[0051] FIG. 1 exemplarily shows a basic structural modification example of a magnetic component MCMP. The magnetic component MCMP includes a magnetic core MCR.

[0052] The magnetic core MCR may have a topology having a closed loop for a magnetic flux path MFP. The magnetic core may include an upper part and a lower part that together form a closed loop.

[0053] Furthermore, the magnetic component includes a first material M1 for at least partially inducing a stray magnetic flux. The first material may be a resin or a plastic material. The first material may include magnetic particles or other magnetic components that are embedded in the first material as a matrix material or that provide a single phase without a phase boundary together with the first material.

[0054] Furthermore, the magnetic component includes a coil CL having a winding W.

[0055] The core MCR and the coil CL may be embedded in a first material.

[0056] FIG. 2 shows the magnetic flux during operation of a basic structural modification example of the magnetic component.

[0057] The first material as a potting compound having magnetic, thermal and electrical properties or in the potting compound realizes the induction of magnetic flux together with direct induction in the solid (magnetic core). Thus, by controlling more magnetic flux, improved properties can be obtained.

[0058] The embedding material, together with the first material, helps to induce and concentrate the floating magnetic flux lines FL in the floating region STA outside the solid magnetic material.

[0059] In addition to the concentration of the magnetic flux lines FL, the embedding material may also help to conduct heat to the external environment. Additionally, the embedding material may be used for proper electrical insulation of the conductive parts of the component.

Description of Reference Numerals

[0060] CL... Coil, CLT... Closed-loop topology, FL... Magnetic flux line, M1... First material, MCMP... Magnetic component, MCR... Magnetic core, MFP... Magnetic flux path, MP_SO... Magnetic path in solid core, MP_ST... Magnetic path in floating region, RE... Resin material, plastic material, STA... Floating region, W... Winding.

Claims

1. A magnetic core, A coil having a winding wound around the magnetic core, A magnetic component comprising: The magnetic component, A main magnetic flux path within the magnetic core, and A stray magnetic flux region outside the magnetic core, Further comprising, The stray magnetic flux region or path is at least partially embedded in or induced by a first material, The first material is a thermal conductivity filler or potting material, Magnetic component.

2. The magnetic component according to claim 1, which is a coupled inductor having two inductive segments magnetically or electromagnetically coupled to each other.

3. The magnetic component according to claim 1 or 2, which is a coupled inductor having more than two inductive segments magnetically or electromagnetically coupled to each other.

4. The magnetic component according to any one of claims 1 to 3, wherein the first material has a magnetic permeability μ_1 of 1.5 ≤ μ_1 ≤ 26.

5. The magnetic component according to any one of claims 1 to 4, wherein the magnetic core has a magnetic permeability μ_2 of 26 ≤ μ_2 ≤ 27000.

6. The magnetic component according to any one of claims 1 to 5, wherein the first material has a thermal conductivity of 0.5 W / mK or more.

7. The magnetic component according to any one of claims 1 to 6, wherein the first material has an electrical resistivity r of r ≥ 10 kV / mm.

8. The magnetic core includes an upper magnetic core portion and a lower magnetic core portion and / or one or more components, The upper magnetic core portion and the lower magnetic core portion form a casing having a front opening and a rear opening, The magnetic component according to any one of claims 1 to 7.

9. The magnetic component according to claim 8, wherein the coil is mounted on the casing.

10. The coil includes a first terminal connection portion and a second terminal connection portion, The first terminal connection portion and the second terminal connection portion extend outward from the front surface or the front opening of the component, The magnetic component according to any one of claims 1 to 9.

11. The magnetic component according to any one of claims 1 to 10, wherein the first material is disposed around the coil and / or the magnetic core.

12. The lower magnetic core portion includes a central column for at least partially mounting the coil, The central column extends upward from the mounting plane of the lower magnetic core portion and is displaced from the center of the mounting plane toward the front opening. The magnetic component according to any one of claims 1 to 11.

13. The magnetic component according to any one of claims 1 to 12, wherein the surface of the first material is flush with the rear opening.

14. The magnetic component according to any one of claims 1 to 13, wherein a part of the first material protrudes from the rear opening.

15. The magnetic component, a bobbin mounted on the lower magnetic core portion, further comprises, The coil is wound around the bobbin. The magnetic component according to any one of claims 1 to 14.

16. The magnetic component according to any one of claims 1 to 15, wherein the bobbin comprises or consists of a plastic material.

17. Insulating paper and / or an insulating film disposed between the coil and the upper magnetic core portion, further comprises, the magnetic component according to any one of claims 1 to 16.

18. The magnetic component, a thermal conductive interface material between the first material and the upper magnetic core portion and / or between the first material and the lower magnetic core portion, further comprises, The thermal conductive interface material, has a hardness equal to or less than the hardness of the first material, or, has a hardness equal to or less than the hardness of the upper magnetic core portion, or, has a hardness equal to or less than the hardness of the lower magnetic core portion, has a hardness of, The magnetic component according to any one of claims 1 to 17.

19. The magnetic component according to any one of claims 1 to 18, wherein the first material at least partially fills the casing of the component from the rear opening to the front opening.

20. The magnetic component according to any one of claims 1 to 19, wherein the first material at least partially fills the casing from the mounting plane of the lower magnetic core portion to the upper magnetic core portion.

21. The magnetic core, the lower magnetic core portion and / or the upper magnetic core portion comprises or consists of a material selected from Fe—Si based alloys, Fe—Ni based alloys, MnZn or MnZn based alloys, NiZn or NiZn based alloys, the magnetic component according to any one of claims 1 to 20.

22. The magnetic component according to any one of claims 1 to 21, wherein the first material comprises or consists of a material selected from a thermosetting phenolic resin, a thermoplastic polyethylene terephthalate (PET), a polyamide (PA), a polyphenylene sulfide (PPS), a polyether ether ketone (PEEK), a polyurethane (PUR), an epoxy, and a silicone resin.

23. The magnetic component according to any one of claims 1 to 22, wherein the front opening and the rear opening are arranged on opposite sides of each other in two parallel and opposite directions of the expansion stress in order to reduce the expansion stress acting on the upper magnetic core portion and the lower magnetic core portion.

24. The magnetic component according to any one of claims 1 to 23, wherein the first material does not completely seal the outer surfaces of the upper magnetic core portion and the lower magnetic core portion.

25. A step of preparing a mold with a coil mounted thereon; A step of potting the mold with a thermally conductive material to form a first material; A step of sealing at least a part of the coil; A step of demolding the first material and the coil from the mold; A step of combining the first material with a magnetic core; A method for manufacturing a magnetic component according to any one of claims 1 to 24, comprising:

26. The mold includes a lower magnetic core portion, The step of combining the first material with the magnetic core includes combining the lower magnetic core portion with an upper magnetic core portion, The first material is disposed or accommodated between the upper magnetic core portion and the lower magnetic core portion. The manufacturing method according to claim 25.

27. A step of mounting a bobbin on the lower magnetic core portion; A step of winding the coil around the bobbin; A step of sealing a part of the coil in the bobbin and the lower magnetic core portion with the first material. The manufacturing method according to claim 25 or 26, further comprising:

28. The mold includes a lower magnetic core portion and an upper magnetic core portion, The step of combining the first material with the magnetic core includes combining the lower magnetic core portion, the upper magnetic core portion, and the first material, and the first material is disposed or accommodated between the upper magnetic core portion and the lower magnetic core portion. The manufacturing method according to any one of claims 25 to 27.

29. placing a thermally conductive interface material between the coil and the first material; The method of manufacturing according to any one of claims 25 to 28, further comprising.

30. preparing a mold including an upper magnetic core portion and a lower magnetic core portion and a coil attached to the mold; potting the mold with a thermally conductive material to form a thermally conductive filler; sealing at least a part of the coil; The method of manufacturing according to any one of claims 25 to 29, including.

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