Magnetic components

Abstract

To provide a magnetic component that can easily control leakage inductance.SOLUTION: A magnetic component includes a core including first and second protrusions extending in a first direction, a first conductor including a first flat wire that defines a first turn that extends around the first protrusion such that a smallest dimension of the first flat wire is parallel or substantially parallel to the first direction, and a second conductor including a second flat wire that defines a second turn that extends around the second protrusion such that a smallest dimension of the second flat wire is parallel or substantially parallel to the first direction. The first and the second turns are adjacent to each other and are off set in two dimensions to define a gap between adjacent turns of the first and the second conductors.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to magnetic components. More specifically, the present invention relates to a gap structure of a magnetic component that can be used to control leakage inductance.

Background Art

[0002] It is known that magnetic components such as inductors or transformers can be embedded in a converter. In magnetic components, leakage inductance enables the converter to function with a wide bandwidth or a wide operating frequency. In the prior art, the amount of leakage inductance cannot be controlled. Leakage inductance can be generated in a gap within a magnetic core.

Summary of the Invention

Problems to be Solved by the Invention

[0003] However, since it is difficult to achieve a desired leakage inductance only with a gap of a certain distance, it is necessary to control the width of the gap to a certain distance. In other words, it is difficult to accurately control the leakage inductance whether the gap is too narrow or too wide.

[0004] Figure 1 shows a known magnetic component 100 comprising a conductor 110, an upper core 120, and a lower core 130. The conductor 110 includes a turned portion 110a wrapped around a projection 130a of the lower core 130 or a projection of the upper core 120, and includes feet 110b that can be attached to a substrate, such as a printed circuit board (PCB). Figure 1 shows a magnetic component 100 having four conductors 110, the four conductors 110 comprising flat wires. The turned portions 110a of the four conductors 110 of the magnetic component 100 are coplanar with each other, and each of the feet 110b extends perpendicular or substantially perpendicular to the plane defined by the turned portions 110a within the manufacturing tolerance range and / or measurement tolerance range, so that the four conductors 110 can be connected to a substrate that is parallel or substantially parallel to the plane defined by the turned portions 110a within the manufacturing tolerance range. In Figure 1, the gap between adjacent turns 110a of the conductor 110 is only one-dimensional (i.e., the gap is a horizontal gap), which makes it difficult to control the leakage inductance. [Means for solving the problem]

[0005] To overcome the above challenges, an exemplary embodiment of the present invention provides a magnetic component in which adjacent turns of a first flat wire conductor and a second flat wire conductor are offset in two dimensions to define a gap between adjacent turns of the first flat wire conductor and the second flat wire conductor, thereby enabling easy control of leakage inductance.

[0006] According to an exemplary embodiment of the present invention, the magnetic component includes a core including a first projection and a second projection extending in a first direction; a first conductor including a first flat wire, the first flat wire defining a first turn extending around the first projection such that the minimum dimension of the first flat wire is parallel or substantially parallel to the first direction; and a second conductor including a second flat wire, the second flat wire defining a second turn extending around the second projection such that the minimum dimension of the second flat wire is parallel or substantially parallel to the first direction. The first and second turns are adjacent to each other and offset in two dimensions to define a gap between the adjacent turns of the first and second conductors.

[0007] The first plane defined by the first turn and the second plane defined by the second turn do not need to be on the same plane. The first conductor may include first and second feet extending in opposite directions, and the second conductor may include first and second feet extending in opposite directions. The first turn may be either a single full turn or a single three-quarter turn, and the second turn may be either a single full turn or a single three-quarter turn.

[0008] The core may include an upper core and a lower core. The upper gap corner of the upper core and the lower gap corner of the lower core closest to the gap may be chamfered. The upper part corner of the upper core opposite the upper gap corner and the lower part corner of the lower core opposite the lower gap corner may both be notched.

[0009] According to an exemplary embodiment of the present invention, a magnetic component assembly includes an upper substrate and a lower substrate, and one magnetic component from various other exemplary embodiments of the present invention mounted between the upper substrate and the lower substrate.

[0010] The magnetic component assembly may further include a first electronic component on the upper surface of the upper substrate. The magnetic component assembly may further include an upper second electronic component mounted on the underside of an upper substrate and a lower second electronic component mounted on the upper surface of a lower substrate. The core may include an upper component corner adjacent to the upper substrate and cut out to accommodate the upper second electronic component, and a lower component corner adjacent to the lower substrate and cut out to accommodate the lower second electronic component.

[0011] According to an exemplary embodiment of the present invention, the magnetic component includes a core, an upper core including an upper surface and a lower surface not parallel to the upper surface; a lower core including an upper surface and a lower surface not parallel to the upper surface, wherein the upper surface of the upper core and the lower surface of the lower core are parallel or substantially parallel; a core including a first groove and a second groove extending through the core; a first conductor including a first flat wire, the first flat wire extending through the first groove such that the minimum dimension of the first flat wire is not parallel to the minimum dimension of the core; and a second conductor including a second flat wire, the second flat wire extending through the second groove such that the minimum dimension of the second flat wire is not parallel to the minimum dimension of the core. The first groove and the second groove and the first conductor and the second conductor are arranged to define a gap between adjacent turns of the first conductor and the second conductor.

[0012] The first plane defined by the first conductor and the second plane defined by the second conductor may be coplanar or substantially coplanar. The first conductor may include first and second feet extending in opposite directions, and the second conductor may include first and second feet extending in opposite directions. The height of the gap may be less than the height of the first and / or second conductor. The first and second grooves may be contained within the upper core and / or lower core. The upper surface of the upper core may include a notched upper component corner, and the lower surface of the lower core may include a notched lower component corner.

[0013] According to an exemplary embodiment of the present invention, a magnetic component assembly includes an upper substrate and a lower substrate, and one magnetic component from various other exemplary embodiments of the present invention mounted between the upper substrate and the lower substrate.

[0014] The magnetic component assembly may further include a first electronic component on the upper surface of the upper substrate. The magnetic component assembly may further include an upper second electronic component mounted on the lower surface of an upper substrate and a lower second electronic component mounted on the upper surface of a lower substrate. The upper surface of the upper core may include an upper component corner cut out to accommodate the upper second electronic component, and the lower surface of the lower core may include a lower component corner cut out to accommodate the lower second electronic component.

[0015] The above and other features, elements, characteristics, steps, and advantages of the present invention will become more apparent from the following detailed description of exemplary embodiments of the present invention with reference to the attached drawings. [Brief explanation of the drawing]

[0016] [Figure 1] This is a perspective view of a known magnetic component in which the turns of a flat wire coil lie on the same plane. [Figure 2] This is a perspective view of a magnetic component according to a first exemplary embodiment of the present invention, in which the turned portions of the flat wire coil are not on the same plane. [Figure 3] Figure 2 is a perspective view of the magnetic component, with the upper magnetic core shown as transparent. [Figure 4] Figure 2 is a perspective view of the flat wire coil of the magnetic component. [Figure 5] Figure 2 is a side view of the magnetic component. [Figure 6] This is a perspective view of a magnetic component according to a second exemplary embodiment of the present invention, in which adjacent corners of the magnetic core are chamfered and the opposite corner is notched. [Figure 7] Figure 6 is a perspective view of the magnetic component with the upper printed circuit board removed. [Figure 8] FIG. 7 is a perspective view of a magnetic component, in which the upper magnetic core is shown as being transparent. [Figure 9] FIG. 6 is a side view of the magnetic component. [Figure 10] FIG. 7 is a perspective view of a magnetic component according to a third exemplary embodiment of the present invention, in which the cross-section of the magnetic core is trapezoidal. [Figure 11] FIG. 10 is a perspective view of a magnetic component, in which the upper magnetic core is shown as being transparent. [Figure 12] FIG. 10 is a side view of the magnetic component. [Figure 13] FIG. 10 is a perspective view of a magnetic component according to a third exemplary embodiment of the present invention, in which the cross-section of the magnetic core is trapezoidal and the corner on the opposite side of the magnetic core is cut away. [Figure 14] FIG. 13 is a perspective view of a magnetic component, in which the upper magnetic core is shown as being transparent. [Figure 15] FIG. 13 is a side cross-sectional view of the magnetic component. DETAILED DESCRIPTION OF THE INVENTION

[0017] FIGS. 2 to 5 show a magnetic component 10 according to a first exemplary embodiment of the present invention. The magnetic component 10 includes a conductor 11 and a core having an upper core 12 and a lower core 13. As shown in Figures 2 to 5, the magnetic component 10 may include four conductors 11, but any number of conductors 11 may be two or more. Each conductor 11 may be defined by a flat wire. Each conductor 11 may include copper, brass, or other suitable conductive materials. The width of the flat wire may be greater than the thickness of the flat wire. The conductor 11 may include two legs 11b connected by a turn 11a. The two legs 11b may extend in opposite directions (e.g., upward and downward) so that the conductor 11 can be connected to two opposing parallel substrates (not shown in Figures 2 to 5, but shown as an upper substrate 25 and a lower substrate 26 in Figures 6 to 9), or the two legs 11b may extend in the same direction so that the conductor 11 can be connected to the same substrate (not shown). The substrate may be, for example, a printed circuit board (PCB) or other suitable substrate. The magnetic component assembly may include the magnetic component 10 connected to one or two substrates.

[0018] The projections 12a, 13a may extend from the upper core 12 or the lower core 13 along the first direction. The number of projections 12a, 13a may be the same as the number of conductors 11. The projections 12a, 13a may have any preferred cross-sectional shape, including the rectangular cross-sectional shape shown in Figure 3. Each turn 11a of the conductor 11 may wrap around or extend around the corresponding projection 12a or 13a. As shown in Figures 3 and 4, the turn 11a may be a single turn, for example, including a single three-quarter turn or a single full turn. The surface of the flat wire of the turn 11a defined by the width direction is perpendicular or substantially perpendicular to the first direction within the manufacturing tolerance range and / or measurement tolerance range, i.e., the thickness or minimum dimension of the flat wire is parallel or substantially parallel to the first direction within the manufacturing tolerance range and / or measurement tolerance range.

[0019] In Figures 2, 3, and 5, the core may include two parts, namely the upper core 12 and the lower core 13, but any number of parts may be used. For example, the core may include a single part or three or more parts. The core, including the upper core 12 and the lower core 13, may be made of ferrite such as MnZn ferrite, or any other suitable magnetic material.

[0020] In Figures 2 to 5, the protrusion 12a extends only from the lower core 12, and the protrusion 13a extends only from the lower core 13, with the protrusions 12a and 13a positioned to align with each other. However, other arrangements are also possible. For example, the protrusion may extend only from the upper core 12, or only from the lower core 13, or the protrusion may extend from both the upper core 12 and the lower core 13 so that the protrusions are positioned to align with each other.

[0021] Figure 5 shows that the planes defined by adjacent turns 11a of the conductor 11 are not coplanar. The adjacent first and second turns 11a are offset in two dimensions to define a gap between them. The leakage inductance is determined by the geometric shape of the first and second turns 11a, particularly the distance between them. By changing the distance between the first and second turns 11a, the leakage inductance changes. Increasing the distance between the first and second turns 11a increases the leakage inductance. A gap having a specific distance between the first and second turns 11a can generate a desired leakage inductance. In a gap that is offset in two dimensions, the leakage inductance can be generated more easily. That is, the internal step defined by the upper core 12 and the lower core 13 makes it easier to determine the leakage inductance.

[0022] Figures 6 to 9 show a magnetic component 20 according to a second exemplary embodiment of the present invention. The magnetic component 20 includes a conductor 21 and a core having an upper core 22 and a lower core 23. Figure 6 shows the magnetic component 20 mounted between an upper substrate 25 and a lower substrate 26 to define a magnetic component assembly. The upper substrate 25 and the lower substrate 26 may be, for example, a PCB or other suitable substrate. An electronic component 25a may be mounted on the upper part of the upper substrate 25, an electronic component 25b may be placed on the lower surface of the upper substrate 25, and an electronic component 26b may be placed on the upper surface of the lower substrate 26. The electronic components 25a, 25b, and 26b may be active components such as integrated circuits (ICs) and transistors, or passive components such as resistors, capacitors, and inductors. The upper substrate 25 and the lower substrate 26, which may contain the electronic components 25a, 25b, and 26b, may be used in conjunction with other exemplary embodiments of the present invention. Electronic component 25a can be called the first electronic component, electronic component 25b the upper second electronic component, and electronic component 26b the lower second electronic component.

[0023] As shown in Figures 6 to 9, the magnetic component 20 may include four conductors 21, but any number of conductors 21 may be used. Each conductor 21 may be defined by a flat wire. Each conductor 21 may include copper, brass, or other suitable conductive materials. The width of the flat wire may be greater than the thickness of the flat wire. The conductor 21 may include two legs 21b connected by a turn 21a. The two legs 21b may extend in opposite directions (e.g., upward and downward) so that the conductor 21 can be connected to two opposing parallel upper substrates 25 and lower substrates 26, or the two legs 21b may extend in the same direction so that the conductor 21 can be connected to the same substrate (not shown). The turn 21a may wrap around a corresponding projection 23a.

[0024] The projections 22a, 23a may extend from the upper core 22 or the lower core 23 along the first direction. The number of projections 22a, 23a may be the same as the number of conductors 21. The projections 22a, 23a may have any preferred cross-sectional shape, including the rectangular cross-sectional shape shown in Figure 8. Each turn 21a of the conductor 21 may wrap around or extend around the corresponding projection 22a or 23a. As shown in Figure 8, the turn 21a may be a single turn, including, for example, a single three-quarter turn or a single full turn. The surface of the flat wire of the turn 21a defined by the width direction is perpendicular or substantially perpendicular to the first direction within the manufacturing tolerance range and / or measurement tolerance range, i.e., the thickness or minimum dimension of the flat wire is parallel or substantially parallel to the first direction within the manufacturing tolerance range and / or measurement tolerance range.

[0025] In Figures 6 to 9, the core may include two parts, namely the upper core 12 and the lower core 13, but any number of parts may be used. For example, the core may include a single part or three or more parts. The core, including the upper core 12 and the lower core 13, may be made of ferrite such as MnZn ferrite, or any other suitable magnetic material.

[0026] In Figures 6 to 9, the protrusion 22a extends only from the lower core 22, and the protrusion 23a extends only from the lower core 23, with the protrusions 22a and 23a positioned to align with each other. However, other arrangements are also possible. For example, the protrusion may extend only from the upper core 22, or only from the lower core 23, or the protrusion may extend from both the upper core 22 and the lower core 23 so that the protrusions are positioned to align with each other.

[0027] Figure 9 shows that the planes defined by adjacent turns 21a of the conductor 21 are not coplanar. The adjacent first and second turns 21a are set to be offset in two dimensions so as to define a gap between them. The leakage inductance is determined by the geometric shape of the first and second turns 21a, in particular the distance between the first and second turns 21a. By changing the distance between the first and second turns 21a, the leakage inductance changes. By increasing the distance between the first and second turns 21a, the leakage inductance increases. A gap having a specific distance between the first and second turns 21a can generate a desired leakage inductance. In a gap set to be offset in two dimensions, the leakage inductance can be generated more easily. That is, the internal step defined by the upper core 22 and the lower core 23 makes it easier to determine the leakage inductance.

[0028] As shown in Figures 6-9 and 2-5, the upper core 22 and lower core 23 are different from the upper core 12 and lower core 13. Two differences are that the upper core 22 may have a corner 22b, and the lower core 23 may have a corner 23b. The corners 22b and 23b are the corners closest to the gap between adjacent turn portions 21a, extend along the length of the magnetic component, and may be chamfered. The corners 22b and 23b allow the upper core 22 and lower core 23 to be brought closer to each other, which may enable miniaturization of the magnetic component 20. The corners 22b and 23b may be called upper gap corners or lower gap corners.

[0029] Further differences between the upper core 22 and the lower core 24 are that the upper core 22 may include a notched corner 22c on the upper surface of the upper core 22 (for example, on the opposite side of corner 22b), and the lower core 23 may include a notched corner 23c on the lower surface of the lower core (for example, on the opposite side of corner 23b). The corners 22c and 23c may be notched to accommodate the corresponding electronic components 25b and 26b, thereby enabling miniaturization of the magnetic component assembly. Including corners 22b and 23b in addition to corners 22c and 23c can increase the amount of space available to accommodate the corresponding electronic components 25b and 26b, thereby enabling further miniaturization of the magnetic component assembly. The corners 22b and 23b may be called upper component corners or lower component corners.

[0030] Figures 10 to 12 show a magnetic component 30 according to a third exemplary embodiment of the present invention. The magnetic component 30 includes a conductor 31 and a core having an upper core 32 and a lower core 33. As shown in Figures 10 to 12, the magnetic component 30 may include two conductors 31, but any number of conductors 31 may be used. Each conductor 31 may be defined by a flat wire. Each conductor 31 may include copper, brass, or other suitable conductive materials. The width of the flat wire may be greater than the thickness of the flat wire. The conductor 31 may include two legs 31b connected by a turn 31a. The two legs 31b may extend in opposite directions (e.g., upward and downward) so that the conductor 31 can be connected to two opposing parallel substrates (not shown in Figures 10 to 12, but shown in Figures 6 to 9 as an upper substrate 25 and a lower substrate 26), or the two legs 31b may extend in the same direction so that the conductor 31 can be connected to the same substrate (not shown). The substrate may be, for example, a printed circuit board (PCB) or other suitable substrate. The magnetic component assembly may include the magnetic component 30 connected to one or two substrates.

[0031] The grooves 32b may extend in a first direction along the lower surface of the upper core 32. The number of grooves 32b may be the same as the number of conductors 31. The grooves 32b may have any preferred cross-sectional shape, including the rectangular cross-sectional shape shown in the cross-sectional view of Figure 12. Each turn portion 31a of the conductor 31 may extend through the corresponding groove 32b. As shown in Figure 11, the turn portion 31a may be a single turn portion, for example, including a single quarter turn portion. The surface of the flat wire of the turn portion 31a, defined by the width direction, is not parallel to the upper surface of the upper core 32 and not parallel to the lower surface of the lower core 33; that is, the thickness or minimum dimension of the flat wire is not parallel to the thickness or minimum dimension of the core.

[0032] In Figures 10 to 12, the core may include two parts, namely the upper core 32 and the lower core 33, but any number of parts may be used. For example, the core may include a single part or three or more parts. The core, including the upper core 32 and the lower core 33, may be made of ferrite such as MnZn ferrite or any other suitable magnetic material. As shown in Figure 12, the cross-sectional shape of the upper core 32 and the lower core 33 may be a right-angled trapezoid shape having two adjacent right angles, one acute angle, and one obtuse angle, and having two opposing parallel or substantially parallel lines and two opposing non-parallel lines within the manufacturing tolerance range and / or measurement tolerance range. The lines that the upper core 32 and the lower core 33 face are such that they are not parallel to the top surface of the upper core 32 and not parallel to the bottom surface of the lower core 33. In this way, the non-parallel lines connecting the obtuse and acute angles of the upper core 32 (i.e., the bottom surface of the upper core 32) and the non-parallel lines connecting the obtuse and acute angles of the lower core 33 (i.e., the top surface of the lower core 33) can face each other.

[0033] As shown in Figures 11 and 12, the upper core 32 may include a projection 32a such that a gap is defined between the inductors 31. Alternatively, the lower core 33 may include a projection, or each of the upper core 32 and the lower core 33 may include a projection such that a gap is defined between the conductors 31 within the upper core 32 and / or the lower core 33.

[0034] Figure 12 shows that the planes defined by adjacent turns 31a of the conductor 31 are coplanar or substantially coplanar within the manufacturing tolerance range and / or measurement tolerance range, but are not parallel to the upper surface of the upper core 32 and not parallel to the lower surface of the lower core 33, as described above. As shown in Figure 12, the height of the gap may be less than the height of the turns 31a. The leakage inductance is determined by the geometric shapes of the first turns 31a and the second turns 31a, in particular the distance between the first turns 31a and the second turns 31a. By changing the distance between the first turns 31a and the second turns 31a, the leakage inductance changes. By increasing the distance between the first turns 31a and the second turns 31a, the leakage inductance increases. A gap having a specific distance between the first turns 31a and the second turns 31a can generate a desired leakage inductance. In a gap defined by a projection 32a, leakage inductance can be generated more easily. In other words, the internal step defined by the protrusion 32a makes it easier to determine the leakage inductance.

[0035] Figures 13 to 15 show a magnetic component 40 according to a fourth exemplary embodiment of the present invention. The magnetic component 40 includes a conductor 41 and a core having an upper core 42 and a lower core 43. As shown in Figures 13 to 15, the magnetic component 40 may include two conductors 41, but any number of conductors 41 may be used. Each conductor 41 may be defined by a flat wire. Each conductor 41 may include copper, brass, or other suitable conductive materials. The width of the flat wire may be greater than the thickness of the flat wire. The conductor 41 may include two legs 41b connected by a turn 41a. The two legs 41b may extend in opposite directions (e.g., upward and downward) so that the conductor 41 can be connected to two opposing parallel substrates (not shown in Figures 13 to 13, but shown in Figures 6 to 9 as an upper substrate 25 and a lower substrate 26), or the two legs 41b may extend in the same direction so that the conductor 41 can be connected to the same substrate (not shown). The substrate may be, for example, a printed circuit board (PCB) or other suitable substrate. The magnetic component assembly may include the magnetic component 40 connected to one or two substrates.

[0036] The grooves 42b may extend in a first direction along the lower surface of the upper core 42. The number of grooves 42b may be the same as the number of conductors 41. The grooves 42b may have any preferred cross-sectional shape, including the rectangular cross-sectional shape shown in the cross-sectional view of Figure 15. Each turn portion 41a of the conductor 41 may extend through the corresponding groove 42b. As shown in Figure 14, the turn portion 31a may be a single turn portion, for example, including a single quarter turn portion. The surface of the flat wire of the turn portion 41a, defined by the width direction, is not parallel to the upper surface of the upper core 42 and not parallel to the lower surface of the lower core 43; that is, the thickness or minimum dimension of the flat wire is not parallel to the thickness or minimum dimension of the core.

[0037] In Figures 13 to 15, the core may include two parts, namely the upper core 42 and the lower core 43, but any number of parts may be used. For example, the core may include a single part or three or more parts. The core, including the upper core 42 and the lower core 3, may be made of ferrite such as MnZn ferrite or any other suitable magnetic material. As shown in Figure 15, the cross-sectional shape of the upper core 42 and the lower core 43 may be a right-angled trapezoid shape having two adjacent right angles, acute angles and obtuse angles, and two opposing parallel or substantially parallel lines and two opposing non-parallel lines within the manufacturing tolerance range and / or measurement tolerance range. The lines that the upper core 42 and the lower core 43 face are such that the lines are not parallel to the top surface of the upper core 42 and not parallel to the bottom surface of the lower core 43. This means that the non-parallel lines connecting the obtuse and acute angles of the upper core 42 (i.e., the bottom surface of the upper core 42) and the non-parallel lines connecting the obtuse and acute angles of the lower core 43 (i.e., the top surface of the lower core 43) can face each other.

[0038] As shown in Figures 14 and 15, the upper core 42 may include a projection 42a such that a gap is defined between the inductors 41. Alternatively, the lower core 43 may include a projection, or each of the upper core 42 and the lower core 43 may include a projection such that a gap is defined between the conductors 41 within the upper core 42 and / or the lower core 43.

[0039] Figure 15 shows that the planes defined by adjacent turns 41a of the conductor 41 are coplanar or substantially coplanar within the manufacturing tolerance range and / or measurement tolerance range, but are not parallel to the upper surface of the upper core 42 and not parallel to the lower surface of the lower core 43, as described above. The leakage inductance is determined by the geometric shape of the first turn 41a and the second turn 41a, in particular the distance between the first turn 41a and the second turn 41a. By changing the distance between the first turn 41a and the second turn 41a, the leakage inductance changes. By increasing the distance between the first turn 41a and the second turn 41a, the leakage inductance increases. A gap having a specific distance between the first turn 41a and the second turn 41a can generate a desired leakage inductance. In a gap defined by a projection 42a, the leakage inductance can be generated more easily. That is, an internal step defined by the projection 42a makes it possible to determine the leakage inductance more easily.

[0040] As shown in Figures 13-15 and 10-12, the upper core 42 and lower core 43 differ from the upper core 32 and lower core 33. Two differences are that the upper core 42 may include a notched corner 42c on the upper surface of the upper core 43, and the lower core 43 may include a notched corner 43c on the lower surface of the lower core 43. The corners 42c and 43c may be notched to accommodate corresponding electronic components, similar to how the corners 22c and 23c accommodate corresponding electronic components 25b and 26b in a second exemplary embodiment, thereby enabling miniaturization of the magnetic component assembly including the magnetic component 40.

[0041] The magnetic components 10, 20, 30, and 40 can be used as inductors or transformers. The magnetic components 10, 20, 30, and 40 may be included in a converter such as a DC-DC converter, a DC-AC converter, or an AC-DC converter. For example, the magnetic components 10, 20, 30, and 40 may be transformers in a converter including an upper and lower substrate, and the electronic components on the upper and lower substrates may be other components of the converter.

[0042] It should be understood that the foregoing description is merely illustrative of the present invention. Those skilled in the art can devise various alternative and modified forms without departing from the present invention. Accordingly, the present invention is intended to encompass all such alternative, modified, and variant forms that fall within the scope of the appended claims.

Claims

1. A magnetic component, A core including a first projection and a second projection extending in a first direction, A first conductor comprising a first flat wire, wherein the first flat wire defines a first turn extending around a first projection such that the minimum dimension of the first flat wire is parallel or substantially parallel to the first direction, A second conductor including a second flat wire, the second flat wire defining a second turn extending around the second projection such that the minimum dimension of the second flat wire is parallel or substantially parallel to the first direction, A magnetic component in which the first turn portion and the second turn portion are adjacent to each other, and are set to be offset in two dimensions so as to define a gap extending between adjacent turn portions of the first conductor and the second conductor within the core, such that the first turn portion and the second turn portion do not overlap when viewed from the first direction.

2. The magnetic component according to claim 1, wherein the first plane defined by the first turn portion and the second plane defined by the second turn portion are not on the same plane.

3. The first conductor includes a first foot and a second foot extending in opposite directions. The magnetic component according to claim 1, wherein the second conductor includes a first foot and a second foot extending in opposite directions.

4. The first turn section is either a single full turn section or a single three-quarter turn section. The magnetic component according to claim 1, wherein the second turn portion is either a single full turn portion or a single three-quarter turn portion.

5. The magnetic component according to any one of claims 1 to 4, wherein the core includes an upper core and a lower core.

6. A magnetic component, A core including a first projection and a second projection extending in a first direction, A first conductor comprising a first flat wire, wherein the first flat wire defines a first turn extending around a first projection such that the minimum dimension of the first flat wire is parallel or substantially parallel to the first direction, A second conductor including a second flat wire, the second flat wire defining a second turn extending around the second projection such that the minimum dimension of the second flat wire is parallel or substantially parallel to the first direction, The first turn portion and the second turn portion are adjacent to each other and are set to be offset in two dimensions so as to define a gap between the adjacent turn portions of the first conductor and the second conductor. The core includes an upper core and a lower core, The upper core includes an upper gap corner which is located between the adjacent turn portions and is the corner closest to the gap, The lower core includes a lower gap corner which is located between the adjacent turn portions and is the corner closest to the gap, The upper and lower gap corners of the magnetic component are chamfered.

7. The magnetic component according to claim 6, wherein both the upper component corner of the upper core on the opposite side of the upper gap corner and the lower component corner of the lower core on the opposite side of the lower gap corner are notched.

8. A magnetic component assembly, Upper circuit board and lower circuit board, A magnetic component assembly comprising a magnetic component according to any one of claims 1 to 4, mounted between the upper substrate and the lower substrate.

9. The magnetic component assembly according to claim 8, further comprising a first electronic component on the upper surface of the upper substrate.

10. The upper second electronic component attached to the lower surface of the upper substrate, The lower second electronic component is mounted on the upper surface of the lower substrate, The aforementioned core is An upper component corner portion adjacent to the upper substrate and cut out to accommodate the upper second electronic component, The magnetic component assembly according to claim 8, further comprising: a lower component corner portion adjacent to the lower substrate and cut out to accommodate the lower second electronic component.

11. A magnetic component, It is the core, An upper core including an upper surface and a lower surface not parallel to the upper surface, A lower core including an upper surface and a lower surface not parallel to the upper surface, wherein the upper surface of the upper core and the lower surface of the lower core are parallel or substantially parallel, A core including a first groove and a second groove extending through the core, A first conductor including a first flat wire, wherein the first flat wire extends through the first groove such that the minimum dimension of the first flat wire is not parallel to the minimum dimension of the core, A second conductor comprising a second flat wire, wherein the second flat wire extends through the second groove such that the minimum dimension of the second flat wire is not parallel to the minimum dimension of the core, A magnetic component in which the first groove and the second groove and the first conductor and the second conductor are arranged to define a gap between adjacent turned portions of the first conductor and the second conductor.

12. The magnetic component according to claim 11, wherein the first plane defined by the first conductor and the second plane defined by the second conductor are on the same plane or substantially on the same plane.

13. The first conductor includes a first foot and a second foot extending in opposite directions. The magnetic component according to claim 11, wherein the second conductor includes a first foot and a second foot extending in opposite directions.

14. The magnetic component according to any one of claims 11 to 13, wherein the height of the gap is less than the height of at least one of the first conductor and the second conductor.

15. The magnetic component according to any one of claims 11 to 13, wherein the first groove and the second groove are contained within the upper core.

16. The magnetic component according to any one of claims 11 to 13, wherein the first groove and the second groove are contained within the lower core.

17. The upper surface of the upper core includes a notched upper component corner, The magnetic component according to any one of claims 11 to 13, wherein the lower surface of the lower core includes a notched lower component corner.

18. A magnetic component assembly, Upper circuit board and lower circuit board, A magnetic component assembly comprising a magnetic component according to any one of claims 11 to 13, mounted between the upper substrate and the lower substrate.

19. The magnetic component assembly according to claim 18, further comprising a first electronic component on the upper surface of the upper substrate.

20. The upper second electronic component attached to the lower surface of the upper substrate, The lower second electronic component is mounted on the upper surface of the lower substrate, The upper surface of the upper core includes an upper component corner cut out to accommodate the upper second electronic component, The magnetic component assembly according to claim 18, wherein the lower surface of the lower core includes a lower component corner cut out to accommodate the lower second electronic component.

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