Highly coupled inductor
The highly coupled inductor with parallel coils and insulation addresses leakage inductance issues, enhancing efficiency and reducing volume for high-power electronic devices.
Patent Information
- Application Number
- JP2025004166U
- Authority / Receiving Office
- JP · JP
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2025-12-02
- Publication Date
- 2026-02-16
- Estimated Expiration
- 2035-12-02
Smart Images
Figure 0003254757000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to an inductor, and more particularly to a highly coupled inductor with high output and reduced leakage inductance. [Background technology]
[0002] In the application of transformers and inductance elements, leakage inductance, together with the distributed capacitance in the electrical circuit and the distributed capacitance in the transformer coil, forms an oscillatory circuit, causing the electrical circuit to oscillate and radiate electromagnetic energy to the outside, resulting in electromagnetic interference. Furthermore, during the transmission process, leakage inductance and distributed capacitance cause inrush current, increasing losses. The current development trend for electronic devices is toward high power and high efficiency. Therefore, in order to improve the operating efficiency of electronic devices, it is important to develop transformers and inductance elements with high power and reduced leakage inductance. Summary of the Invention [Problem to be solved by the invention]
[0003] The problem that the present invention aims to solve is to provide a highly coupled inductor in response to the shortcomings of the prior art. [Means for solving the problem]
[0004] To solve the above problems, the present invention provides a highly coupled inductor, which includes at least one main core having an accommodating space passing through it, a first coil removably mounted in the accommodating space, at least one second coil having an attachment portion removably mounted in the space defined by the first coil, and a sub-core having a protrusion removably mounted in the space defined by the second coil, the protrusion being removably mounted on the attachment portion, and the sub-core, the second coil, and the first coil being mounted in the accommodating space of the main core so as to be integrally assembled. [Effects of the Invention]
[0005] The advantages of this invention are that the highly coupled inductor has multiple coils arranged in parallel, which results in high output, improved coupling efficiency, and reduced leakage inductance, and the overall volume of the inductor is reduced, making it easier to assemble small electronic devices. [Brief explanation of the drawings]
[0006] [Figure 1] 1 is an exploded view of a highly coupled inductor according to a first embodiment of the present invention; [Figure 2] 1 is a partially exploded schematic diagram of a highly coupled inductor according to a first embodiment of the present invention; [Figure 3] 1 is an assembly diagram of a highly coupled inductor according to a first embodiment of the present invention; [Figure 4] FIG. 4 is a schematic cross-sectional view taken along the line IV-IV in FIG. [Figure 5] 1 is an exploded view of a highly coupled inductor according to a second embodiment of the present invention; [Figure 6] 10 is an exploded view of a highly coupled inductor according to a third embodiment of the present invention; DETAILED DESCRIPTION OF THE INVENTION
[0007] [First Example] 1 to 4, FIG. 1 is an exploded view of a highly coupled inductor 100a according to a first embodiment of the present invention, FIG. 2 is a partially exploded view of the highly coupled inductor 100a according to the first embodiment of the present invention, FIG. 3 is an assembled view of the highly coupled inductor 100a according to the first embodiment of the present invention, and FIG. 4 is a cross-sectional view taken along the line IV-IV in FIG. 3. As shown in FIG. 1, the highly coupled inductor 100a includes a main core 1, a first coil 2, at least one second coil 3, and a sub-core 4. The main core 1 has an accommodating space S extending therethrough. The first coil 2 is removably mounted within the accommodating space S. The at least one second coil 3 has an attachment portion 3e and is removably mounted within the space defined by the first coil 2. The sub-core 4 has a protrusion 41 and is removably mounted within the space defined by the at least one second coil 3. The sub-core 4, at least one second coil 3, and the first coil 2 are correspondingly arranged in the receiving space S of the main core 1 so as to be assembled together. In practical applications, the main core 1 and the sub-core 4 may be made of ferrite or other soft magnetic materials, but are not limited thereto. In this embodiment, the main core 1 may be an integrally molded core, and the sub-core 4 may be a convex core, but the present invention is not limited thereto.
[0008] In this embodiment, the first coil 2 may be a gate-type or Ω-type coil having a gap G. Specifically, the first coil 2 is composed of a first portion 21, a second portion 22, and a pair of connecting portions 23. The first portion 21 and the second portion 22 may be gate-type coils having similar sizes and shapes. However, the first portion 21 and the second portion 22 are not in contact with each other, and there is a gap between them. The first portion 21 and the second portion 22 are connected together by the pair of connecting portions 23.
[0009] The main core 1 and the first coil 2 are insulated, the first coil 2 and the second coil 3 are insulated, and the second coil 3 and the sub-core 4 are insulated.
[0010] More specifically, the first portion 21 includes a pair of first vertical pins 21a, 21b and a first beam 21c. The pair of first vertical pins 21a, 21b are connected by the first beam 21c. The second portion 22 includes a pair of second vertical pins 22a, 22b and a second beam 22c. The pair of second vertical pins 22a, 22b are connected by the second beam 22c. One connecting portion 23 connects the bottom of the first vertical pin 21a to the bottom of the second vertical pin 22a. The other connecting portion 23 connects the bottom of the first vertical pin 21b to the bottom of the second vertical pin 22b.
[0011] In this embodiment, the second coil 3 may be gate-shaped. The second coil 3 has a pair of vertical pins 3a, 3b and a beam 3c. The pair of vertical pins 3a, 3b are each perpendicular to the beam 3c and are connected by the beam 3c. One end of each of the pair of vertical pins 3a, 3b is connected to a contact pad 3d.
[0012] More specifically, the pair of vertical pins 3a, 3b are perpendicular to the contact pad 3d, and the two contact pads 3d extend toward each other from the portions connected to the pair of vertical pins 3a, 3b, respectively. The two contact pads 3d have a space between their opposing ends, which is defined as a mounting portion 3e.
[0013] Referring to FIG. 2, FIG. 2 is a partially exploded schematic diagram of a highly coupled inductor 100a according to a first embodiment of the present invention. As can be seen from FIG. 2, the housing space S is a T-shaped space that passes through the main core 1. When assembling the highly coupled inductor 100a, the sub-core 4 is disposed within the space defined by the second coil 3, and the protrusion 41 of the sub-core 4 is disposed on the mounting portion 3e. A portion of the second coil 3 is disposed within the gap G of the first coil 2, and a portion of the first coil 2 is disposed parallel to a portion of the second coil 3. However, there is a gap between the first coil 2 and the second coil 3. That is, the first coil 2 and the second coil 3 are insulated from each other. It should be noted that if the first coil 2 and the second coil 3 are made of an insulating material or coated with an insulating material to insulate the first coil 2 and the second coil 3 from each other, there is no need to have a gap between them.
[0014] When a portion of the second coil 3 is provided in the gap G of the first coil 2 and a portion of the first coil 2 is arranged in parallel with a portion of the second coil 3, the connection portion 23 and the contact pad 3d extend in opposite directions.
[0015] Referring to Figures 3 and 4, when the highly coupled inductor 100a is assembled, the accommodating space S is a T-shaped space that penetrates the main iron core 1, and at least one side of the first coil 2 and the second coil 3 is exposed to the outside of the accommodating space S, and therefore at least one side of the connection portion 23 is also exposed to the outside of the accommodating space S.
[0016] [Second Example] Referring to FIG. 5, FIG. 5 is an exploded schematic diagram of a highly coupled inductor 100b according to a second embodiment of the present invention. The main core 1, first coil 2, second coil 3, and sub-core 4 of the second embodiment are substantially identical in structure to the main core 1, first coil 2, second coil 3, and sub-core 4 of the first embodiment, respectively, except that the number of second coils 3 shown in FIG. 5 is one or more (two second coils 3 is used as an example). Depending on the actual application, the number of second coils 3 may be two, three, or four or more, but the present invention is not limited thereto. The assembly method of the above components is substantially the same as the assembly method of the highly coupled inductor 100a shown in FIGS. 1 to 4, and will not be described again here.
[0017] It is particularly noteworthy that the second coil 3 of the highly coupled inductor 100b of the present invention includes a first portion 31 and a second portion 32, which are similar in shape and size and have a gap therebetween. The first portion 31 has a pair of first vertical pins 31a, 31b and a first beam 31c connected therebetween. Each of the pair of first vertical pins 31a, 31b has a contact pad 31d at each end. The two contact pads 31d are perpendicular to the pair of first vertical pins 31a, 31b and extend toward each other. The second portion 32 has a pair of second vertical pins 32a, 32b and a second beam 32c connected therebetween. Each of the pair of second vertical pins 32a, 32b has a contact pad 32d at each end. The two contact pads 32d are perpendicular to the pair of second vertical pins 32a, 32b and extend toward each other.
[0018] Similarly, there is a space between the two contact pads 31d, and there is also a space between the two contact pads 32d. In the second embodiment, both of these spaces are defined as the attachment portion 3e.
[0019] Similarly, when assembling the highly coupled inductor 100b, the secondary core 4 is provided in the space defined by the second coil 3, and the protrusion 41 of the secondary core 4 is provided on the attachment portion 3e.
[0020] Similarly, the main core 1 and the first coil 2 are insulated, the first coil 2 and the second coil 3 are insulated, and the second coil 3 and the sub-core 4 are insulated.
[0021] [Third Example] Referring to Fig. 6, Fig. 6 is an exploded schematic diagram of a highly coupled inductor 100c according to a third embodiment of the present invention. The first coil 2 and second coil 3 shown in Fig. 6 have substantially the same structures as the first coil 2 and second coil 3 of the highly coupled inductor 100a according to the first embodiment shown in Fig. 1, and therefore the first coil 2 and second coil 3 shown in Fig. 6 will not be described again here. The highly coupled inductor 100c according to the third embodiment differs from the highly coupled inductor 100a according to the first embodiment and the highly coupled inductor 100b according to the second embodiment in that the main core 1 of the highly coupled inductor 100c shown in Fig. 6 is double-C or double-E shaped.
[0022] Specifically, the main core 1 of the highly coupled inductor 100a according to the first embodiment shown in Figures 1 to 4 and the main core 1 of the highly coupled inductor 100b according to the second embodiment shown in Figure 5 are integrally molded and have an accommodation space S penetrating through the inside. Furthermore, the sub-cores 4 and the main core 1 of the highly coupled inductors 100a and 100b are independent and separate members. A difference from the highly coupled inductor 100a according to the first embodiment and the highly coupled inductor 100b according to the second embodiment is that the main core 1 of the highly coupled inductor 100c according to the third embodiment includes a first core 11 and a second core 12, and the first core 11 and the second core 12 may be symmetrical E-shaped cores.
[0023] More specifically, the first core 11 has a first core body 11a, a pair of first extensions 11b and 11c, and a first intermediate portion 11d. The pair of first extensions 11b and 11c and the first intermediate portion 11d define a groove in the first core body 11a. The second core 12 has a second core body 12a, a pair of second extensions 12b and 12c, and a second intermediate portion 12d. The pair of second extensions 12b and 12c and the second intermediate portion 12d define a groove in the second core body 12a.
[0024] More specifically, the first core 11 and the second core 12 are arranged symmetrically. The pair of first extension portions 11b, 11c are perpendicular to the first core body 11a and extend toward the second core 12. The pair of second extension portions 12b, 12c are perpendicular to the second core body 12a and extend toward the first core 11. The first extension portion 11b and the second extension portion 12b correspond to each other and extend toward each other. The first extension portion 11c and the second extension portion 12c correspond to each other and extend toward each other. The first intermediate portion 11d and the second intermediate portion 12d correspond to each other. During assembly, the first core 11 and the second core 12 are joined, the first extension portion 11b and the second extension portion 12b abut each other, the first extension portion 11c and the second extension portion 12c abut each other, a portion of the first portion 21 is provided in a groove defined on the first core body 11a by the pair of first extension portions 11b, 11c and the first intermediate portion 11d, and a portion of the second portion 22 is provided in a groove defined on the second core body 12a by the pair of second extension portions 12b, 12c and the second intermediate portion 12d.
[0025] The first intermediate portion 11d and the second intermediate portion 12d are similar to the sub-core 4 of the highly coupled inductor 100a according to the first embodiment shown in Figures 1 to 4 and the sub-core 4 of the highly coupled inductor 100b according to the second embodiment shown in Figure 5. Specifically, during assembly, the first intermediate portion 11d and the second intermediate portion 12d abut and couple to each other to become similar to the sub-core 4 of the highly coupled inductor 100a according to the first embodiment shown in Figures 1 to 4 and the sub-core 4 of the highly coupled inductor 100b according to the second embodiment shown in Figure 5. The sub-core 4 is provided in a space defined by the first coil 2.
[0026] It should be particularly noted that the first intermediate portion 11d has a first protrusion 11d', and the second intermediate portion 12d has a second protrusion 12d'. The first protrusion 11d' and the second protrusion 12d' correspond to each other. Even though the first protrusion 11d' and the second protrusion 12d' abut against each other during assembly, their shapes and sizes match each other, and they are both provided within the mounting portion 3e of the second coil 3.
[0027] It should be noted that when the highly coupled inductor 100c according to the third embodiment of the present invention shown in FIG. 6 is fully assembled, its appearance is substantially the same as the assembled diagram of the highly coupled inductor 100a according to the first embodiment of the present invention shown in FIG.
[0028] [Beneficial Effects of Examples] One of the beneficial effects of this invention is that the highly coupled inductor has multiple coils arranged in parallel, which increases output power, improves coupling efficiency, and reduces leakage inductance. In addition, the overall volume of the inductor is reduced, making it easier to assemble small electronic devices. [Explanation of symbols]
[0029] 100a, 100b, 100c: Highly coupled inductors 1: Main core 11: First iron core 11a: First core body 11b, 11c: 1st stretching section 11d: 1st intermediate part 11d': First convex part 12: Second core 12a: Second core body 12b, 12c: 2nd stretching section 12d: 2nd middle part 12d': Second convex part 2: First coil 21: Part 1 21a, 21b: First vertical pin 21c: First beam 22:Second part 22a, 22b: Second vertical pin 22c: Second beam 23: Connection 3: Second coil 3a, 3b: Vertical pin 3c:Beam 3D:Contact pad 3e: Mounting part 31: Part 1 31a, 31b: First vertical pin 31c: First beam 31d, 32d: Contact pads 32:Second part 32a, 32b: Second vertical pin 32c: Second beam 4: Sub-core 41: Convex S: Containment space G: air gap
Claims
1. At least one main core having an accommodation space passing through the interior thereof; a first coil removably provided in the accommodation space; at least one second coil having an attachment portion and removably disposed within the space defined by the first coil; a secondary core having a protrusion and removably provided in a space defined by the second coil, The protrusion is removably provided on the mounting portion, A highly coupled inductor, wherein the secondary core, the second coil, and the first coil are correspondingly arranged in the accommodating space of the main core so as to be assembled together.
2. The highly coupled inductor according to claim 1 , wherein the accommodation space is a T-shaped space, and at least one side of the first coil is exposed to the outside of the accommodation space.
3. The highly coupled inductor according to claim 1 , wherein at least one side surface of the protrusion is exposed to the outside of the accommodation space.
4. the first coil has a gap, and a portion of the second coil is provided in the gap; The highly coupled inductor of claim 1 , wherein the first coil and the second coil have a gap therebetween.
5. The highly coupled inductor according to claim 4 , wherein a portion of the first coil and a portion of the second coil are arranged in parallel.
6. The highly coupled inductor of claim 5 , wherein the first coil has multiple connections.
7. The highly coupled inductor of claim 6 , wherein the second coil has a plurality of contact pads.
8. The highly coupled inductor of claim 7 , wherein the plurality of connecting portions and the plurality of contact pads extend in opposite directions.
9. 10. The highly coupled inductor of claim 1, comprising two main cores that are double C-shaped or double E-shaped.
10. 2. The highly coupled inductor according to claim 1, wherein the main core and the first coil are insulated, the first coil and the second coil are insulated, and the second coil and the sub-core are insulated.