High-voltage-resistant, high-power-density coupled magnetic element and coupled magnetic module
The coupled magnetic element integrates iron cores and coils with adjustable air gaps to enhance voltage resistance and power density, addressing the size issues of conventional inductors and facilitating miniaturization.
Patent Information
- Application Number
- JP2025004101U
- Authority / Receiving Office
- JP · JP
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2025-11-27
- Publication Date
- 2026-01-27
- Estimated Expiration
- 2035-11-27
AI Technical Summary
Conventional inductor elements are large in size and require increased volume or series connection to achieve high voltage resistance, occupying excessive internal space and hindering miniaturization of electronic devices.
A coupled magnetic element comprising a first iron core, external and internal coils, and a second iron core, with adjustable air gaps and optimized magnetic circuit design, integrating two inductors into a single piece to enhance voltage resistance and power density.
The coupled magnetic element achieves high voltage and power density with ultra-low direct current resistance (DCR), optimizing space utilization and enabling miniaturization of electronic devices.
Smart Images
Figure 0003254502000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a magnetic element, and more particularly to a coupled magnetic element having high withstand voltage and high power density. [Background technology]
[0002] In the prior art, the development trend of electronic devices has been toward high performance and high power density. For example, the volume of the inductor used in a power supply device is generally large and occupies a relatively large amount of space, so how to reduce the size of the inductor element has become an important issue in the related technical field.
[0003] Most conventional inductor elements are installed as individual units. To achieve high voltage resistance, it is necessary to increase the volume or connect multiple small inductors in series using the conductive layers of the circuit board. However, this method occupies more internal space, which is disadvantageous for miniaturizing electronic devices. Summary of the Invention [Problem to be solved by the invention]
[0004] The present invention addresses the shortcomings of the prior art by providing a coupled magnetic element with high voltage resistance and high power density. [Means for solving the problem]
[0005] The high-voltage, high-power-density coupled magnetic component includes a first iron core, an external coil, an internal coil, and a second iron core. The first iron core has a storage chamber penetrating two opposing surfaces. The external coil is removably positioned within the storage chamber, and includes two first side columns and a first connecting portion, with both ends of the first connecting portion respectively connected to the top ends of the two first side columns, the first connecting portion and the two first side columns forming a storage space. The internal coil is removably positioned within the storage space, and includes two second side columns, a second connecting portion, and two bottom pin portions, with both ends of the second connecting portion respectively connected to the top ends of the two second side columns, with the bottom ends of each second side column connected to a respective bottom pin portion, the second side columns, the second connecting portion, and the two bottom pin portions forming an arrangement space. The second iron core is removably positioned within the arrangement space.
[0006] The present invention also provides a high-voltage, high-power-density coupled magnetic module, which includes two high-voltage, high-power-density coupled magnetic elements, two first cores connected to each other to form an outer core, and two adjacent bottom pins of two inner coils connected to each other. [Effects of the Invention]
[0007] One of the beneficial effects of the present invention is that, according to an embodiment, the high voltage and high power density coupled magnetic element provided by the present invention has the technical effects of high voltage and high power density. [Brief explanation of the drawings]
[0008] [Figure 1] 1 is a perspective view of a coupled magnetic element with high voltage resistance and high power density according to an embodiment of the present invention; [Figure 2] FIG. 2 is an exploded schematic view of the embodiment shown in FIG. 1. [Figure 3] 2 is a schematic diagram of an internal coil according to an embodiment of the present invention; [Figure 4] 2 is a schematic diagram of an internal coil according to an embodiment of the present invention; [Figure 5] 1 is a perspective view of a high-voltage, high-power-density coupled magnetic module according to an embodiment of the present invention; [Figure 6] FIG. 6 is an exploded schematic view of the embodiment shown in FIG. 5. [Figure 7] 1 is a schematic diagram of two internal coils connected together according to an embodiment of the present invention; [Figure 8] 1 is a schematic diagram of two internal coils connected together according to an embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION
[0009] Referring to Figures 1 to 4, Figure 1 is a perspective view of a coupled magnetic element 1 with high voltage resistance and high power density according to one embodiment of the present invention. Figure 2 is an exploded schematic view of the embodiment shown in Figure 1. Figure 3 is a schematic view of an internal coil 14 according to one embodiment of the present invention. Figure 4 is a schematic view of an internal coil 14 according to one embodiment of the present invention. The difference between Figures 3 and 4 is the viewing angle.
[0010] The high-voltage, high-power-density coupled magnetic element 1 includes a first iron core 11, an external coil 13, an internal coil 14, and a second iron core 12. The first iron core 11 has a storage chamber S1 penetrating two opposing surfaces. The external coil 13 is removably positioned within the storage chamber S1 and includes two first side columns 131 and a first connecting portion 132. Both ends of the first connecting portion 132 are respectively connected to the top ends of the two first side columns 131, and the first connecting portion 132 and the two first side columns 131 form a storage space S2. The internal coil 14 is removably positioned in the storage space S2, and includes two second side columns 141, a second connecting portion 142, and two bottom pin portions 143, with both ends of the second connecting portion 142 respectively connected to the top ends of the two second side columns 141, and with the bottom ends of each second side column 141 respectively connected to the bottom pin portions 143, and the second side columns 141, the second connecting portion 142, and the two bottom pin portions 143 forming an arrangement space S3. The second iron core 12 is removably positioned in the arrangement space S3.
[0011] As shown in Figures 1 and 2, each first side column 131 includes a pillar body 1311 and a pin 1312, and the pin 1312 is located at the bottom end of the pillar body 1311, extends toward the outside of the pillar body 1311, and protrudes from the first iron core 11.
[0012] 2 to 4, for the internal coil 14, each bottom pin portion 143 includes a body 1431 and a base 1432. The body 1431 is connected to the base 1432. The two bases 1432 are arranged opposite each other and are located outside the two second side columns 141, respectively. Each body 1431 has a side 1431a and a hypotenuse 1431b. Each side 1431a is connected to a corresponding second side column 141, and a slot G is formed between the two hypotenuses 1431b. According to one embodiment, the bodies 1431 have a geometric shape, and a slot G is formed between the matching bodies 1431. For example, in this embodiment, the body 1431 is generally a right triangle, with three sides being the hypotenuse 1431b, the edge 1431a, and the base, and the base is continuous (integrally formed) with the base 1432. According to one embodiment, the width of the slot G (i.e., the distance between the two hypotenuses 1431b) is in the range of 0.1 mm to 0.5 mm.
[0013] Referring again to FIG. 1, according to the embodiment shown in FIG. 1, the pin 1312 is located between two opposing bases 1432, and the two bases 1432 may correspond to each other.
[0014] The first iron core 11 and the second iron core 12 may be made of ferrite or a soft magnetic material. The outer shape of the first iron core 11 is, for example, rectangular. The outer shape of the second iron core 12 is, for example, block-like. The external coil 13 has a generally arched shape. The external coil 13 may be, but is not limited to, a flat coil. The external coil 13 may be made of a pressed copper plate or other types of conductive material. The internal coil 14 may be partially covered by the external coil 13. The two second side pillars 141 and the second connecting portion 142 of the internal coil 14 have a generally arched shape. The internal coil 14 may be, but is not limited to, a flat coil. The internal coil 14 may be made of a pressed copper plate or other types of conductive material.
[0015] 1 to 4, the first iron core 11, the external coil 13, and the second iron core 12 form a first inductor, and the first iron core 11, the internal coil 14, and the second iron core 12 form a second inductor. The gap between the first iron core 11 and the second iron core 12 forms an air gap. The first iron core 11 and the external coil 13 may be in direct contact or may not be in contact (or may be insulated), and the second iron core 12 and the external coil 13 may be in contact or may not be in contact. The second iron core 12 and the internal coil 14 may also be in contact or may not be in contact. The external coil 13 and the internal coil 14 are insulated from each other. By controlling the contact relationship and gap arrangement between the above elements, the magnetic flux path and coupling strength can be effectively adjusted, thereby achieving the effect of controlling the inductance. At the same time, the coil winding method and core structure design disclosed in this invention shortens the conduction path and reduces the direct current resistance (DCR), thereby achieving ultra-low DCR characteristics and improving the efficiency and overall power density of the inductor element.
[0016] Furthermore, in one embodiment, the high-voltage and high-power-density coupled magnetic element 1 of the present invention can also realize an ultra-high-voltage magnetic element structure by insulating the first iron core 11, the external coil 13, the internal coil 14, and the second iron core 12 with each other.
[0017] Referring to Figures 5 to 8, and again to Figure 2, Figure 5 is a perspective view of a coupled magnetic module Z with high withstand voltage and high power density according to one embodiment of the present invention. Figure 6 is an exploded schematic view of the embodiment shown in Figure 5. Figure 7 is a schematic view of two internal coils 14 connected together according to one embodiment of the present invention. Figure 8 is a schematic view of two internal coils 14 connected together according to one embodiment of the present invention. The difference between Figures 7 and 8 is the viewing angle.
[0018] The high-voltage, high-power-density coupled magnetic module Z includes two high-voltage, high-power-density coupled magnetic elements 1. As shown in Fig. 5, two first cores 11 are connected together to form an outer core 100, which is integrally molded in one embodiment. The pin 1312 of the first side column 131 is located at the bottom end of the column body 1311 (see Fig. 2) and extends outward from the column body 1311, protruding from the outer core 100.
[0019] In the two internal coils 14 of the high-voltage, high-power-density coupled magnetic module Z, two adjacent bottom pin portions 143 are connected to each other. As shown in FIG. 8 , the two bottom pin portions 143 are connected to each other by two bases 1432. Here, the two bases 1432 connected to each other are defined as a common base 1430. In some embodiments, the common base 1430 is integrally molded. It should be noted that the sizes of the two outer bases 1432 may be the same or different. In some embodiments, the size of the common base 1430 and the size of the outer base 1432 may also be different. For example, the size of the common base 1430 may be larger or smaller than the size of the outer base 1432. The structural design of the common substrate 1430 not only enhances the mechanical stability and conductive reliability between the internal coils 14, but also effectively shortens the current conduction path, reduces the contact resistance, and achieves the purpose of reducing the direct current resistance (DCR), thereby improving the efficiency and power density of the entire module.
[0020] [Beneficial Effects of Examples] One of the beneficial effects of the present invention is that the high voltage and high power density coupled magnetic element provided by the present invention has the technical effects of high voltage and high power density according to an embodiment.
[0021] Furthermore, in one embodiment, the present invention's high-voltage, high-power-density coupled magnetic element optimizes the magnetic circuit design to achieve a high coupling coefficient between the two inductors, allowing them to interact with each other and improve energy conversion efficiency. At the same time, multiple air gaps are arranged between the first and second cores, which not only effectively improves the withstand voltage capability but also allows for the adjustment of magnetic flux distribution and inductance value as needed. Furthermore, the present invention effectively shortens the current path through a special coil winding method and common substrate structural design, reducing conductor losses and achieving ultra-low DC resistance (DCR). Through this comprehensive design, the present invention overcomes the technical bottlenecks of existing high-voltage, high-power-density magnetic elements on the market while achieving low DC resistance, thereby helping to reduce the volume of electronic devices and meeting the demand for high performance and miniaturization.
[0022] In other words, the first inductor is formed by a first iron core, an external coil, and a second iron core, while the second inductor is formed by a first iron core, an internal coil, and a second iron core. The air gap between the two allows the inductance to be adjusted to meet the circuit requirements. In one embodiment, the coupled magnetic element of the present invention integrates two inductor elements into a single piece, effectively reducing the number and footprint of elements on a printed circuit board assembly (PCBA), shortening the current conduction path, and reducing contact resistance and overall DC resistance. Meanwhile, the present invention maximizes space utilization and power density, enabling products to be more compact and functional, effectively resolving the challenges of the prior art.
[0023] The high-voltage and high-power-density coupled magnetic module has the high-voltage and high-power-density coupled magnetic element, and therefore naturally has the technical effects of the high-voltage and high-power-density coupled magnetic element. [Explanation of symbols]
[0024] Z... High voltage and high power density coupled magnetic module 1...High voltage resistance and high power density coupled magnetic element 100...External core 11...First core 12...Second core 13...External coil 131...First side pillar 1311...Column 1312...pin 132...First connection 14...Internal coil 141...Second side pillar 142...Second connection 143...Bottom pin part 1430...Common base 1431...Main body 1431a...edge line 1431b...hypotenuse 1432...substrate G...Slot S1...Storage chamber S2...Storage space S3...placement space
Claims
1. a first core having a receiving chamber extending through two opposing surfaces; an external coil removably positioned within the storage chamber, the external coil including two first side columns and a first connecting portion, both ends of the first connecting portion being respectively connected to the top ends of the two first side columns, the first connecting portion and the two first side columns forming a storage space; an internal coil removably positioned within the storage space, the internal coil including two second side posts, a second connecting portion, and two bottom pin portions, each of which has both ends connected to a top end of the two second side posts, and a bottom end of each of the second side posts connected to a respective bottom pin portion, the two second side posts, the second connecting portion, and the two bottom pin portions forming an arrangement space; a second iron core removably positioned within the arrangement space; A coupled magnetic element with high voltage resistance and high power density.
2. 2. The high-voltage, high-power-density coupled magnetic element according to claim 1, wherein each of the first side columns includes a column body and a pin, the pin being located at a bottom end of the column body and extending toward the outside of the column body while protruding from the first iron core.
3. 2. The high-voltage and high-power-density coupled magnetic element of claim 1, wherein each of the bottom pin portions includes a main body and a base, the main body is connected to the base, the two bases are arranged opposite each other and are respectively located outside the two second side poles, each of the main bodies has a side line and a hypotenuse, each of the side lines is respectively connected to each of the second side poles, and a slot is formed between the two hypotenuses.
4. 4. The high-voltage and high-power-density coupled magnetic element according to claim 3, wherein each of the first side columns includes a column body and a pin, the pin being located at the bottom end of the column body and extending toward the outside of the column body while protruding from the first iron core, and each of the pins being located between two opposing bases and corresponding to the two opposing bases.
5. 4. The high-voltage, high-power-density coupled magnetic element according to claim 3, wherein the main body is generally a right-angled triangle, the three sides of which are the hypotenuse, the edge, and the base, and the base is connected to the base.
6. The high-voltage and high-power-density coupled magnetic element according to claim 1 includes: The two first cores are connected together to form an outer core, In the two internal coils, two adjacent bottom pins are connected to each other. A coupled magnetic module with high voltage resistance and high power density.
7. 7. The high-voltage and high-power-density coupled magnetic module according to claim 6, wherein each of the first side columns includes a column body and a pin, the pin being located at a bottom end of the column body, extending toward the outside of the column body, and protruding from the outer iron core.
8. 7. The high-voltage and high-power-density coupled magnetic module of claim 6, wherein each of the bottom pins includes a main body and a base, the main body is connected to the base, the two bases are arranged opposite each other and are respectively located outside the two second side columns, each of the main bodies has a side line and a hypotenuse, each of the side lines is respectively connected to each of the second side columns, and there is a slot between two adjacent hypotenuses.
9. 9. The high-voltage and high-power-density coupled magnetic module according to claim 8, wherein each of the first side columns includes a column body and a pin, the pin being located at the bottom end of the column body, extending toward the outside of the column body and protruding from the outer iron core, and each of the pins being located between two adjacent bases and corresponding to two adjacent bases.
10. 9. The high-voltage and high-power-density coupled magnetic module of claim 8, wherein each of the main bodies is generally a right-angled triangle, the three sides of which are the hypotenuse, the edge, and the base, and the base is connected to the base.