Flat Coupled Inductor
The flat coupled inductor addresses the issue of high height in current inductors by employing a core member and coils with arch-shaped bodies and pins, achieving reduced height and enhanced power density for efficient noise filtering and power conversion.
Patent Information
- Application Number
- JP2025004165U
- Authority / Receiving Office
- JP · JP
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2025-12-02
- Publication Date
- 2026-02-13
- Estimated Expiration
- 2035-12-02
AI Technical Summary
Current inductor technologies have high overall height, limiting their applications and necessitate improvements in structural design for high voltage resistance and high power density.
A flat coupled inductor design comprising a core member with opposing openings, first and second coils with arch-shaped bodies and pins, and a rational magnetic circuit to achieve high coupling and withstand voltage, reducing height while maintaining high power density.
The design achieves reduced inductor height, high voltage resistance, and improved power density, enabling efficient noise filtering and power conversion.
Smart Images
Figure 0003254631000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to an inductor structure, and more particularly to a flat coupled inductor. [Background technology]
[0002] Inductors have the functions of noise filtering, transient current suppression, EMI reduction, and power conversion. They are used in a wide range of applications in electronics, such as transformers, energy storage, sensors, induction motors, filters, and electromagnetic relays.
[0003] With current technology, the overall height of inductors is high, limiting their applications. To meet people's usage needs, inductor elements must have the characteristics of high voltage resistance and high power density.
[0004] Therefore, how to overcome these drawbacks by improving the structural design is one of the important issues to be solved in this field. Summary of the Invention [Problem to be solved by the invention]
[0005] The technical problem that the present invention aims to solve is to address the shortcomings of the prior art and provide a flat coupled inductor. [Means for solving the problem]
[0006] To solve the above technical problems, one technical solution adopted by the present invention provides a flat coupled inductor including a core member, a first coil, and a second coil. The core member has a first opening and a second opening on opposing sides, respectively, and the core member includes a first core body and a second core body. The second core body and the first core body are coupled together, with an accommodation space between the first core body and the second core body, which is connected to the first opening and the second opening, respectively. The first coil includes a first arch-shaped body, a first pin, a second pin, and a third pin. The first arch-shaped body has a first accommodation space, and the first arch-shaped body is located within the accommodation space. The first pin is connected to the first arch-shaped body and extends from the first opening, away from the first core body. The second and third pins are each connected to the first arch-shaped body, extend from the second opening, and extend away from the first core body. The second coil includes a second arch-shaped body and two inner pins, the second arch-shaped body having a second accommodation space, the second arch-shaped body being located within the first accommodation space and spaced apart from the first arch-shaped body. Each inner pin is each connected to the second arch-shaped body, extend from the second opening, and extend away from the first core body, and each inner pin is located between the second and third pins. [Brief explanation of the drawings]
[0007] [Figure 1] 1 is a perspective view of a flat coupled inductor according to an embodiment of the present invention; [Figure 2] FIG. 2 is a perspective schematic view of the embodiment shown in FIG. [Figure 3] FIG. 2 is a perspective schematic view of the embodiment shown in FIG. [Figure 4] FIG. 2 is an exploded schematic view of the embodiment shown in FIG. [Figure 5] FIG. 2 is an exploded schematic view of the embodiment shown in FIG. [Figure 6] 2 is a top view of the embodiment shown in FIG. 1, with the first core body omitted. [Figure 7]2 is a bottom view of the embodiment shown in FIG. 1, with the second core body omitted. DETAILED DESCRIPTION OF THE INVENTION
[0008] Please refer to Figures 1 to 7. Figure 1 is a perspective schematic view of a flat coupled inductor Z according to an embodiment of the present invention. Figure 2 is a perspective schematic view of the embodiment shown in Figure 1. Figure 3 is a perspective schematic view of the embodiment shown in Figure 1. Figure 4 is an exploded schematic view of the embodiment shown in Figure 1. Figure 5 is an exploded schematic view of the embodiment shown in Figure 1. Figure 6 is a top view of the embodiment shown in Figure 1, omitting the first core body 11. Figure 7 is a bottom view of the embodiment shown in Figure 1, omitting the second core body 12.
[0009] The flat coupled inductor Z includes a core member 1, a first coil 2, and a second coil 3. Opposing side surfaces of the core member 1 have a first opening 1a and a second opening 1b, respectively, and the core member 1 includes a first core body 11 and a second core body 12. The second core body 12 is coupled to the first core body 11, and an accommodation space S exists between the first core body 11 and the second core body 12, and the accommodation space S communicates with the first opening 1a and the second opening 1b, respectively. The first coil 2 includes a first arch-shaped body 20, a first pin 21, a second pin 22, and a third pin 23. The first arch-shaped body 20 has a first accommodation space S1, and the first arch-shaped body 20 is located within the accommodation space S. The first pin 21 is connected to the first arch-shaped body 20 and extends from the first opening 1a, away from the first core body 11. The second pin 22 and the third pin 23 are each connected to the first arch-shaped body 20 and extend from the second opening 1b, away from the first core body 11. The second coil 3 includes a second arch-shaped body 31 and two inner pins 32. The second arch-shaped body 31 has a second accommodating space S2 and is located within the first accommodating space S1, with a gap between it and the first arch-shaped body 20. Each inner pin 32 is connected to the second arch-shaped body 31, passes through the second opening 1b, and extends away from the first core body 11. Each inner pin 32 is located between the second pin 22 and the third pin 23. In this embodiment, the first pin 21 , the second pin 22 and the third pin 23 further protrude from the bottom surface 122 of the second core body 12 .
[0010] The arch shape may be a "U" shape or a "C" shape. According to some embodiments, the arch shape is an "Ω" shape. According to some embodiments, the first core body 11 and the second core body 12 (core member 1) can be made of ferrite or a flexible magnetic material. According to some embodiments, the first coil 2 and the second coil 3 can be flat coils, but are not limited to this. The first coil 2 and the second coil 3 can be made of stamped copper plates or other conductive materials. The first coil 2 and the second coil 3 are insulated from each other, e.g., they are not in physical contact with each other (e.g., there is a gap G1 between the first arch-shaped body 20 and the second arch-shaped body 31, which is a "U"-shaped channel as shown in FIGS. 6 and 7). The provision of the gap G1 and the provision of other gaps (see below for details) achieves an ultra-high withstand voltage effect. The size of the gap G1 can be flexibly adjusted by the manufacturer or user according to actual needs, and by changing the size of the gap G1, the inductance of the first inductor generated by the first coil 2 and the second inductor generated by the second coil 3 can be controlled.
[0011] 4 and 5, the first arch-shaped body 20 of the flat coupled inductor Z includes two side arm segments 201 and a connecting segment 202. Both ends of the connecting segment 202 are connected to the side arm segments 201, respectively, and the first pin 21 is connected to the center of the connecting segment 202.
[0012] As shown in Figures 2 to 5, each inner pin 32 of the flat coupled inductor Z includes an extension 321 and a solder pad 322, with the solder pad 322 connected to the extension 321 and located below the second core body 12. This structure facilitates a flat design of the flat coupled inductor Z and reduces the overall height. According to some embodiments, the vertical height of the flat coupled inductor Z is 3 to 6 millimeters (mm). In the embodiment shown in Figure 2, a spacer G2 is disposed between the solder pad 322 of the flat coupled inductor Z and the second core body 12.
[0013] 1, the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32 of the flat coupled inductor Z extend in the same direction. However, the present invention is not limited thereto. In other embodiments, at least one of the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32 can extend in one direction, and at least one of the other pins can extend in another direction. At least one of the pins can also extend in a different direction. For example, the first pin 21, the second pin 22, and the third pin 23 can extend downward (toward the second core body 12), and the two inner pins 32 can extend upward (toward the first core body 11). In another embodiment, the first pin 21, the second pin 22, and the third pin 23 extend upward (toward the first core body 11), and the two inner pins 32 extend downward (toward the second core body 12). The present invention is not particularly limited, and the extending direction of the pins can be adjusted according to the user's needs. In some embodiments, increasing the extending length of the pins (the first pin 21, the second pin 22, the third pin 23, and the two inner pins 32) allows multiple components to be placed below the core member 1, thereby improving the power density of the inductor.
[0014] According to some embodiments, there is one second opening 1b, and the second pin 22, the third pin 23, and the two inner pins 32 extend from said second opening 1b. In the embodiment shown in Figure 3, there are two second openings 1b, and the second pin 22 extends from one second opening 1b and the third pin 23 extends from another second opening 1b. The two inner pins 32 extend from different second openings 1b, and the two inner pins 32 are located between the second pin 22 and the third pin 23. The second pin 22 and the corresponding inner pin 32 form a notch O, and the third pin 23 and the corresponding inner pin 32 form another notch O.
[0015] Explaining further the structure of the first core body 11 of the flat coupled inductor Z, as shown in FIG. 5 , the first core body 11 includes a first plate 111 and a bump 112. Both side surfaces of the first plate 111 correspond to the first opening 1a and the second opening 1b, respectively, and define a first side surface 111a and a second side surface 111b. The bump 112 is connected to the surface of the first plate 111 facing the second core body 12 and is located within the second accommodating space S2. In this embodiment, the first core body 11 of the flat coupled inductor Z further includes two mounting posts 113, which are connected to the surface of the first plate 111, extend from the first opening 1a toward the second opening 1b, and are located on both sides of the bump 112. One end of each mounting post 113 is aligned with the first side surface 111a of the first plate 111. The other end of the mounting post 113 does not extend to the second side surface 111 b of the first plate 111 .
[0016] To further explain the structure of the second core 12 of the flat coupled inductor Z, the second core 12 of the flat coupled inductor Z includes a second plate 121, one side of which has a hole 1211 that forms part of the first opening 1a. The other side of the second plate 121 has a protrusion 1212 that is located between the two inner pins 32.
[0017] One beneficial effect of the present invention is that the flat coupled inductor provided by the present invention can reduce the height of the inductor and achieve the technical effects of high voltage resistance and high power density through the following technical solution: "The first coil includes a first arch-shaped body, a first pin, a second pin, and a third pin," "The first arch-shaped body has a first accommodating space, the first arch-shaped body is located in the accommodating space, the first pin is connected to the first arch-shaped body, extends from the first opening, and extends in a direction away from the first iron core body; the second pin and the third pin are respectively connected to the first arch-shaped body, extend from the second opening, and extend in a direction away from the first iron core body." This is realized by the technical solutions of "the second coil includes a second arch-shaped body and two inner pins, the second arch-shaped body has a second accommodation space, the second arch-shaped body is located in the first accommodation space, and each inner pin is respectively connected to the second arch-shaped body and extends out through the second opening and in a direction away from the first core body" and "the two inner pins are located between the second pin and the third pin."
[0018] Furthermore, the flat coupled inductor Z of the present invention achieves a very high coupling coefficient between the two coupled inductors through a rational magnetic circuit design, allowing them to influence each other. Furthermore, a high withstand voltage effect is achieved through the design of the gap between the first coil and the second coil, as well as the size of the spacer (e.g., the spacer between the solder pad and the second core) disposed between the first core and the second core. The combination of the core member, first coil, and second coil according to the present invention reduces the height of the coupled inductor, allowing it to meet application needs.
[0019] Furthermore, according to one embodiment, by increasing the height of the pins (first pin 21, second pin 22, third pin 23, and two inner pins 32), multiple components (e.g., components on a circuit board) can be added below the second core body, which not only reduces the height of the inductor but also improves the power density of the overall product. [Explanation of symbols]
[0020] Z-flat coupled inductor 1 Core material 1a First opening 1b Second opening 11 First core body 111 First Plate 111a First Aspect 111b Second Aspect 112 Bump 113 Attached pillar 12 Second core body 121 Second Plate 1211 holes 1212 Protrusion 122 bottom 2 First coil 20 First arched body 201 Lateral Arm Segment 202 connection segments 21 First Pin 22 Second pin 23 Third Pin 3 Second Coil 31 Second arched body 32 inner pin 321 Stretching section 322 solder pad O-notch G1 Gap G2 spacer S Storage Space S1 First Storage Space S2 Second storage space
Claims
1. an iron core member having a first opening and at least one second opening on each of opposing side surfaces, the iron core member including: a first iron core body; and a second iron core body coupled to the first iron core body and having an accommodating space between the first iron core body and the second iron core body, the accommodating space communicating with the first opening and the second opening, respectively; a first coil having a first accommodating space, the first coil including: a first arch-shaped body positioned within the accommodating space; a first pin connected to the first arch-shaped body, extending from the first opening, and extending in a direction away from the first core body; and a second pin and a third pin connected to the first arch-shaped body, each extending from the second opening, and extending in a direction away from the first core body; a second coil having a second accommodating space, the second coil including: a second arched body located within the first accommodating space; and two inner pins located within the first accommodating space, each connected to the second arched body, extending from the second opening, extending in a direction away from the first core body, and located between the second pin and the third pin; Equipped with 1. A flat coupled inductor comprising:
2. 2. The flat coupled inductor of claim 1, wherein the first arched body includes two side arm segments and a connecting segment, both ends of the connecting segment are respectively connected to the side arm segments, and the first pin is connected to a center of the connecting segment.
3. The flat coupled inductor of claim 1 , wherein the first pin, the second pin, the third pin and the two inner pins extend in the same direction.
4. 2. The flat coupled inductor of claim 1, wherein at least one of the first pin, the second pin, the third pin, and the two inner pins extends in one direction and at least one of the other pins extends in another direction.
5. 2. The flat coupled inductor of claim 1, wherein each of the inner pins includes an extension and a solder pad, the solder pad being connected to the extension and positioned below the second core body, with a spacer between the solder pad and the second core body.
6. The flat coupled inductor of claim 5 , wherein there are two second openings, and each of the inner pins protrudes from a respective one of the second openings.
7. 2. The flat coupled inductor of claim 1, wherein the inner pin corresponding to the second pin forms a notch, and the inner pin corresponding to the third pin forms another notch.
8. 2. The flat coupled inductor of claim 1, wherein the first core body includes a first plate and a bump, both side surfaces of the first plate defining a first side surface and a second side surface corresponding to the first opening and the second opening, respectively, and the bump is connected to a surface of the first plate facing the second core body and is located within the second accommodating space.
9. 9. The flat coupled inductor of claim 8, wherein the first core body further includes two mounting posts, each of which is connected to the surface and extends from the first opening toward the second opening, each of which is located on either side of the bump, and one end of each of which is flush with the first side of the first plate.
10. 8. The flat coupled inductor of claim 7, wherein the second core body includes a second plate, one side of the second plate having a hole that forms part of the first opening, and the other side of the second plate having a protrusion located between the two inner pins.