Slim-type magnetic coupling device with stable voltage resistance characteristics

Abstract

A magnetic coupling device according to one embodiment of the present invention includes a first bobbin including an upper surface, a lower surface facing the upper surface, and an outer surface disposed between the upper surface and the lower surface, the first bobbin including a groove portion disposed inside the outer surface and recessed from the upper surface toward the lower surface, and a first terminal portion and a second terminal portion disposed on the outer surface spaced apart in a first direction, a second bobbin disposed on the groove portion and accommodating a magnetic core, and a first coil and a second coil wound around the second bobbin and spaced apart from each other in the first direction, the first coil including a first winding portion wound around the second bobbin and a first extension portion extending from the first winding portion onto an outer surface of the first bobbin and coupled to the first terminal portion, and the second coil including a second winding portion wound around the second bobbin and a second extension portion extending from the second winding portion onto the outer surface of the first bobbin and coupled to the second terminal portion.

Description

Technical Field

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[0001] The present invention relates to a slim type magnetic coupling device, particularly magnetic components such as an inductor or a transformer by way of example.

Background Art

[0002] For example, as the slimming down of TVs accelerates, there is a great demand for slimming down magnetic components as well, and in order to meet such demands, the size of components is gradually decreasing in a trend to reduce the mounting area and strengthen price competitiveness.

[0003] However, due to the miniaturization of such magnetic components, the withstand voltage characteristics become unstable and problems such as heat generation occur, so there is a need for improvement in this regard.

[0004] By way of example, FIG. 1 shows a conventional EMI filter including a second bobbin 1a formed in a cylindrical donut shape and housing a core therein, a first coil 2a and a second coil 2b wound on both sides sandwiching the central portion of the second bobbin 1a, and a first bobbin 1b having a structure formed separately from the second bobbin 1a and including a groove portion formed in the center so that the first and second coils 2a, 2b can be housed in a state of being wound around the second bobbin 1a, extending on both sides of the groove portion, and having a plurality of terminals provided.

[0005] Such a conventional EMI filter has the following problems, particularly because the terminal portions are concentrated on both side ends respectively.

[0006] 1) The distance between a pair of terminals to which a pair of extension portions on one side of the first coil and the second coil are connected (between 3a and 3d, between 3b and 3c) becomes small, so the withstand voltage characteristics become more unstable due to miniaturization.

[0007] 2) It is difficult to secure a sufficient terminal area due to spatial problems, so when the terminal size increases, the overall component size increases and the withstand voltage characteristics further deteriorate.

[0008] 3) The problem is that there are limits to miniaturization because the length w1 in one direction can only become relatively large. [Overview of the project] [Problems that the invention aims to solve]

[0009] The present invention aims to solve at least one of the aforementioned conventional problems.

[0010] In other words, the present invention provides a magnetic coupling device or magnetic component that is suitable for miniaturization and has stable and improved voltage resistance characteristics by ensuring sufficient distance between terminals. [Means for solving the problem]

[0011] A magnetic coupling device according to one embodiment of the present invention includes a first bobbin having an upper surface, a lower surface facing the upper surface, and an outer surface disposed between the upper surface and the lower surface, a groove portion disposed inside the outer surface and recessed from the upper surface toward the lower surface, and a first terminal portion and a second terminal portion disposed on the outer surface at a distance from each other in a first direction; a second bobbin disposed on the groove portion and housing a magnetic core; and a first coil and a second coil wound on the second bobbin and spaced apart from each other in a first direction, wherein the first coil includes a first winding portion wound on the second bobbin and a first extension portion extending from the first winding portion onto the outer surface of the first bobbin and coupled to the first terminal portion; and the second coil includes a second winding portion wound on the second bobbin and a second extension portion extending from the second winding portion onto the outer surface of the first bobbin and coupled to the second terminal portion.

[0012] In at least one embodiment of the present invention, the second bobbin includes a pair of isolation protrusions, and the first winding portion and the second winding portion are separated by the pair of isolation protrusions.

[0013] In at least one embodiment of the present invention, the starting angle formed by the first extension and the second extension as they emerge from the groove with respect to a virtual straight line connecting the pair of isolation protrusions is 25° or more.

[0014] Furthermore, the starting angle may be 50° or less.

[0015] In at least one embodiment of the present invention, each of the terminal portions is provided at a distance of 5 mm or more from the isolation projection.

[0016] Furthermore, each of the terminal portions may be arranged in alignment with a virtual parallel line that is parallel to a virtual straight line connecting the pair of isolation protrusions at the outermost casing of the first coil or the second coil relative to the isolation protrusion.

[0017] In at least one embodiment of the present invention, the first bobbin includes a pair of bobbin extensions extending from the groove on both sides, wherein the distance from the groove to the outermost edge of the central portion of each bobbin extension is smaller in a predetermined direction than that of the first or second terminal portion.

[0018] Here, a second isolation projection may be formed in the central portion of the bobbin extension.

[0019] Furthermore, in at least one embodiment of the present invention, the first bobbin is formed such that at least a portion of it bulges outward along the shape of the groove.

[0020] In at least one embodiment of the present invention, each of the terminal portions is provided on the first bobbin so as to surround the upper surface, lower surface and outer surface of the first bobbin.

[0021] Here, each of the extensions can be inserted between the outer surface and the terminal portion.

[0022] In at least one embodiment of the present invention, the angle θ1 between the last winding of the first coil and the last winding of the second coil opposite it is 20 to 100°.

[0023] Furthermore, in at least one embodiment of the present invention, the angle θ2 formed by the first terminal portion and the second terminal portion with respect to the center of the second bobbin is 20 to 100°.

[0024] And the ratio of the angles (θ2 / θ1) can be 0.2 to 5.

[0025] In at least one embodiment of the present invention, the first bobbin further includes a third terminal portion and a fourth terminal portion, and each of the first to fourth terminal portions is disposed in each quadrant region of the outer contour of the groove portion.

[0026] In at least one embodiment of the present invention, each of the first extension portion and the second extension portion extends outward from the groove portion while spreading at an angle that gradually increases and is connected to the first terminal portion and the second terminal portion.

[0027] In at least one embodiment of the present invention, the first bobbin further includes a guide groove portion on an outer surface.

[0028] Here, the guide groove portion further includes a first guide groove portion and a second guide groove portion, and each of the first extension portion and the second extension portion may be disposed in the first guide groove portion and the second guide groove portion.

[0029] Also, the guide groove portion may be connected to the groove portion in which the second bobbin is disposed.

[0030] In at least one embodiment of the present invention, the first bobbin includes a radially extending portion that extends radially from the groove portion and in which each terminal portion is provided.

Advantages of the Invention

[0031] According to the present invention, a magnetic component suitable for miniaturization can be obtained.

[0032] Further, the magnetic coupling device or magnetic component according to the present invention stably ensures withstand voltage characteristics despite miniaturization.

[0033] Additional advantages of the present invention will be clearly understood by those skilled in the art from the embodiments of the present invention described below.

Brief Description of the Drawings

[0034] [Figure 1] This figure shows an EMI filter as a conventional magnetic component.

[0035] [Figure 2] This figure shows an EMI filter as one embodiment of the present invention.

[0036] [Figure 3] This is a cross-sectional view of line AA in Figure 2.

[0037] [Figure 4] This figure shows a part of an EMI filter as a second embodiment of the present invention.

[0038] [Figure 5] This figure shows a part of an EMI filter as a third embodiment of the present invention.

[0039] [Figure 6] This figure shows a part of an EMI filter as a fourth embodiment of the present invention. [Modes for carrying out the invention]

[0040] While the present invention can be modified in various ways and has many embodiments, this document will describe specific embodiments illustrated with drawings. However, this should not be understood as limiting the present invention to specific embodiments, but rather as including all modifications, equivalents, or substitutes that fall within the spirit and technical scope of the present invention.

[0041] The suffixes "module" and "part" used herein are solely for the purpose of distinguishing between constituent elements in name and should not be interpreted as presupposing that they are physically or chemically separated or can be separated in that way.

[0042] Terms including ordinal numbers, such as "first," "second," etc., can be used to describe a variety of components, but the components are not limited to those terms. The terms are used solely for the purpose of distinguishing one component from another.

[0043] The term "and / or" is used to include all possible combinations of the items it refers to. For example, "A and / or B" includes all three cases: "A", "B", and "A and B".

[0044] When it is said that one component is "linked" or "connected" to another component, it should be understood that it may be directly linked to or connected to the other component, but there may also be other components in between.

[0045] In the description of the embodiments, the statement that each layer (film), region, pattern, or structure is formed "on" or "under" the substrate, each layer (film), region, pad, or pattern includes all those that are formed directly or interposed by other layers. Furthermore, the criteria for "on" or "under" are, in principle, based on the state shown in the drawings for convenience, unless otherwise expressed in the attributes of each component or between them, and are used only to show the relative positional relationship between components for convenience, and should not be understood as limiting the actual position of the components. For example, "B on top" simply indicates that B is shown on top of A in the drawing, unless otherwise mentioned or unless A or B's attributes require A to be positioned on top of B. In actual implemented products, B may be positioned below A, and B and A may be positioned side by side.

[0046] Furthermore, the thickness and size of each layer (membrane), region, pattern, or structure in the drawings may be altered for clarity and convenience of explanation, and therefore do not directly reflect the actual size.

[0047] The terms used in this application are used solely to describe specific embodiments and are not intended to limit the invention. A singular expression includes plural expressions unless the context clearly indicates otherwise. In this application, terms such as “includes” or “having” are intended to specify the presence of features, figures, stages, operations, components, parts, or combinations thereof as described in the specification, and should be understood not to preemptively exclude the possibility of the presence or addition of one or more other features, figures, stages, operations, components, parts, or combinations thereof.

[0048] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as those generally understood by a person of ordinary skill in the art to which this invention pertains. Terms such as those defined in commonly used dictionaries should be interpreted as having the meaning consistent with their meaning in the context of the relevant art, and should not be interpreted ideally or excessively formally unless expressly defined herein.

[0049] Figure 2 shows an EMI filter embodied as one embodiment of the present invention, and Figure 3 shows a cross-section of the AA line in Figure 2.

[0050] The EMI filter of this embodiment includes a second bobbin 10, a first bobbin 20, a first coil 40, and a second coil 50.

[0051] The second bobbin 10 is formed separately from the first bobbin 20 and houses a magnetic core (not shown) inside. The magnetic core may have a structure formed by winding an amorphous ribbon like a scroll, for example.

[0052] The second bobbin 10 has a roughly circular donut shape, with a pair of isolated protrusions 11a and 11b formed approximately in the center.

[0053] The pair of isolation protrusions 11a and 11b divide the second bobbin 10 into a first region (upper region in the drawing) and a second region (lower region in the drawing), and the two regions are isolated by the isolation protrusions 11a and 11b in terms of the windings of the first coil 40 and the second coil 50.

[0054] The second bobbin 10 may include a lower part with a U-shaped cross-section and an upper part with an inverted U-shaped cross-section, and after housing a magnetic core inside, the upper and lower parts may overlap and be joined together.

[0055] In the second bobbin 10, the first coil 40 is wound in the first region, which is one side region, and the second coil 50 is wound in the second region.

[0056] The first bobbin 20 has a groove 21 formed in the middle, and is seated in the groove 21 with the first coil 40 and the second coil 50 wound around the second bobbin 10.

[0057] The groove portion 21 has a through hole formed in the center, a seating portion extending radially outward from the circumferential edge of the hole, and a circumferential wall formed at a predetermined height from the outer circumference of the seating portion.

[0058] The first bobbin 20 includes a first bobbin extension 22a and a second bobbin extension 22b that extend in the direction of a virtual straight line VL connecting the pair of isolation protrusions 11a and 11b of the second bobbin 10 on both sides of the groove 21.

[0059] Terminal portions (or terminals) 30a, 30b, 30c, and 30d are provided at four locations on the bobbin extensions 22a and 22b on both sides. As shown in Figure 2, the terminal portions 30a, 30b, 30c, and 30d are provided on the outer casing of the groove portion 21 in each quadrant region with respect to the groove portion 21. That is, the first terminal portion 30a is provided in the first quadrant region, the third terminal portion 30b is provided in the second quadrant region, the fourth terminal portion 30c is provided in the third quadrant region, and the second terminal portion 30d is provided in the fourth quadrant region.

[0060] The first terminal section 30a and the second terminal section 30d, and the third terminal section 30b and the fourth terminal section 30c are each spaced apart in the first direction (vertical direction in Figure 2).

[0061] In the bobbin extensions 22a and 22b, the central portion corresponding to the isolation protrusions 11a and 11b is formed with a small distance L1 from the groove 21 to the outermost edge, and the terminal portions 30a, 30b, 30c, and 30d are arranged sufficiently far apart from the central portion, thereby eliminating spatial constraints on their installation and allowing for an increase in the area of ​​the upper or lower surface (mounting surface) of the terminal portions 30a, 30b, 30c, and 30d.

[0062] In other words, the distance L1 is formed to be smaller than the length L2 of the terminal portion in the direction of the virtual straight line VL, and the terminal portions 30a, 30b, 30c, and 30d can be positioned in the bobbin extensions 22a and 22b at a length sufficient in the direction of the virtual straight line VL, thereby making it possible to maintain a compact overall length w1' in the direction of the virtual straight line VL in the EMI filter.

[0063] Furthermore, second isolation protrusions 24a and 24b are formed in the central part of the bobbin extensions 22a and 22b, thereby more reliably isolating the extensions 41a and 41b of the first coil 40 and the extensions 51a and 51b of the second coil 50.

[0064] Furthermore, the extensions 41a and 51a, 41b of the first coil 40 and the extensions 51a and 51b of the second coil 50, which are arranged opposite each other with the virtual straight line VL in between, each extend outwards from the groove 21 at an angle that gradually increases and connects to their respective terminal portions 30a, 30b, 30c, and 30d.

[0065] In this embodiment, the minimum distance ds between the pair of extensions 41a and 51a, and 41b and 51b, is determined by the position of each of the last windings on the second bobbin 10 (this last winding is the part that is directly connected to the extension toward the terminals), and the parts that extend from the last winding outside the groove 21 and connect to the respective terminals 30a, 30b, 30c, and 30d are spaced further apart from each other. With this structure, the EMI filter of this embodiment can stably ensure voltage withstand characteristics.

[0066] In Figure 2, as a typical example, the angle θ1 between the last winding on the left side of the first coil 40 and the last winding on the left side of the second coil 50 is at least 20° and less than or equal to 100°. If the angle θ1 is less than 20°, the distance between the wires of the coil is too small, resulting in a voltage withstand failure. If it is 100° or more, there is structurally insufficient winding space, and overlapping occurs between the wires during winding, which can increase the overall height of the component.

[0067] Furthermore, in Figure 2, the angle θ2 formed by terminal 30b on the first coil 40 side and terminal 30c on the second coil 50 side, relative to the center of the second bobbin 10 or the first coil and second coils 40 and 50, is at least 20° and less than or equal to 100°.

[0068] If the angle θ2 is less than 20°, the distance between wires becomes small when connecting the coil extension, resulting in a voltage withstand failure. If it is 100° or more, the distance between terminals becomes large, and the wire length becomes longer when connecting, causing a problem of high resistance.

[0069] On the other hand, the ratio (θ2 / θ1) between the angles θ1 and θ2 is preferably between 0.2 and 5. If the ratio of the angles is less than 0.2, the overall height of the component may increase due to insufficient space for winding the wire, and if it is greater than 5, the distance between terminals increases, resulting in a longer wire length and higher resistance during connection, which can affect heat generation.

[0070] Figure 3 shows a typical example in which terminals 30a, 30b, 30c, and 30d are provided on the first bobbin 20 and extensions 41a, 41b, 51a, and 51b are connected, specifically the case of the third terminal 30b.

[0071] As shown in Figure 3, the third terminal portion 30b penetrates the first bobbin 20 and is provided so as to surround the upper surface US, lower surface LS, and outer surface SS of the first bobbin 20. The one-sided extension portion 41b of the first coil 40 is connected to the third terminal portion 30b at the outer surface SS. That is, the extension portion 41b emerges from the last winding of the first coil 40 outside the groove portion 21, extends along the upper surface of the bobbin extension portion 22b of the first bobbin 20 while bending at an angle that gradually increases upward, descends to the outer surface SS of the bobbin extension portion 22b, and is inserted and connected between the outer surface SS and the third terminal portion 30b.

[0072] This connection structure between the extensions 41a, 41b, 51a, and 51b and their terminals 30a, 30b, 30c, and 30d allows for a slimmer overall thickness of the EMI filter.

[0073] Furthermore, in the first bobbin 20, the outer surfaces on both sides of the virtual straight line VL sandwiched between them each include protrusions 23a and 23b, which are formed such that at least a portion of them bulge outward in accordance with the shape of the groove 21.

[0074] In this embodiment, the EMI filter has a total length w2' in the direction perpendicular to the virtual straight line VL that is not larger than that of the conventional structure, while the total length w1' in the direction of the virtual straight line VL can be made smaller than that of the conventional structure.

[0075] Figures 4 and 5 represent embodiments different from those described above, and the same reference numerals will be used to describe them in the following description.

[0076] First, in the embodiment shown in Figure 4, the distance d'' between the first terminal portion 30a and the isolation projection 11a of the second bobbin 10 is typically 5 mm. Thus, a separation distance d'' between the first terminal portion 30a and the isolation projection 11a is preferably 5 mm or more. This is because if it is smaller than 5 mm, the voltage withstand characteristic cannot meet the requirement of 2.2 kV.

[0077] Furthermore, the starting angle θs for the extensions 41a and 51a to exit the groove 21 is preferably 25°, and the ending angle θt for connection to the terminals 30a and 30d is preferably 70° or more.

[0078] The embodiment in Figure 5 is an example in which the terminal portions 30a and 30d are separated by the isolation projection 11a as a reference. Preferably, as shown in the figure, the corners of the terminal portions 30a and 30d on the virtual straight line VL side are aligned with the outermost part of the first coil 40. In the embodiment in Figure 5, the starting angle θs of the extensions 41a and 51a is 50°.

[0079] The embodiments shown in Figures 4 and 5 can be implemented in combination. According to this, the separation distance between the first and second terminal portions 30a and 30d and the isolation projection 11a is 5 mm or more, the starting angles θs of the extension portions 41a and 51a are 25° or more and 50° or less, and the ending angles θt of the extension portions 41a and 51a may be 70° or more.

[0080] Conventional EMI filters may have problems where their withstand voltage characteristics do not meet the requirements when the separation distance between the opposing terminals 30a and 30d, and 30b and 30c, which are separated by a virtual straight line VL, is small, and the extensions 41a, 41b, 51a, and 51b are bent. However, the present invention ensures sufficient separation distance between the terminals 30a and 30d, and 30b and 30c, thereby ensuring more stable and satisfactory withstand voltage characteristics compared to conventional EMI filters.

[0081] The following table compares the withstand voltage characteristics of a conventional EMI filter as shown in Figure 1 and an EMI filter according to an embodiment of the present invention as shown in Figure 2.

[0082] [Table 1]

[0083] As shown in the table above, the EMI filter of the embodiment shows a significant increase in the distance between terminals and terminal area. While the withstand voltage of conventional EMI filters was 1.5kV or less and could not meet the requirements, the embodiment exhibits a withstand voltage characteristic of 2.2kV, thus meeting the requirements. Meanwhile, Figure 6 shows yet another embodiment of the present invention.

[0084] The embodiment shown in Figure 6 differs from the previously described embodiment only in the shape and structure of the first bobbin 20.

[0085] The first bobbin 20 of this embodiment includes radial extensions 25a, 25b, 25c, and 25d, each extending radially from four locations in the groove 21 and provided with the respective terminal portions 30a, 30b, 30c, and 30d. The terminal portions 30a, 30b, 30c, and 30d are provided on the radial extensions 25a, 25b, 25c, and 25d, aligned in the radial direction.

[0086] In this embodiment, since the terminals 30a, 30b, 30c, and 30d are aligned radially, there is an advantage in that, compared to other embodiments, the overall length in the direction of the virtual straight line VL can be reduced while maintaining the same area or length of the terminals, thereby enabling miniaturization.

[0087] On the other hand, it goes without saying that the descriptions of the aforementioned embodiments are interchangeable and applicable to each other, provided they are not contradictory and incompatible with one another. Modes for carrying out the invention

[0088] The modes for carrying out the invention have been sufficiently explained in the aforementioned "Modes for Carrying Out the Invention". [Industrial applicability]

[0089] The magnetic coupling device according to the embodiment can be applied to TVs and the like.

Claims

1. A first bobbin including an upper surface, a lower surface facing the upper surface, and an outer surface disposed between the upper surface and the lower surface, a groove disposed inside the outer surface and recessed from the upper surface toward the lower surface, and a first terminal portion and a second terminal portion disposed on the outer surface at a distance from each other in a first direction, A second bobbin, which is positioned on the groove and houses a magnetic core, The second bobbin is wound with a first coil and a second coil that are spaced apart from each other in the first direction, The first coil includes a first winding portion wound on the second bobbin, and a first extension portion extending from the first winding portion onto the outer surface of the first bobbin and coupled to the first terminal portion. The second coil includes a second winding portion wound on the second bobbin, and a second extension portion extending from the second winding portion onto the outer surface of the first bobbin and coupled to the second terminal portion. Each of the first and second terminal portions is provided on the first bobbin so as to surround the upper surface, lower surface and outer surface of the first bobbin. Each of the first and second extensions is a magnetic coupling device inserted between the outer surface and each of the first and second terminal portions.

2. The second bobbin includes a pair of isolation protrusions, The magnetic coupling device according to claim 1, wherein the first winding portion and the second winding portion are separated by the pair of isolation protrusions.

3. The magnetic coupling device according to claim 2, wherein the starting angle formed by the first extension and the second extension as they emerge from the groove is 25° or more with respect to a virtual straight line connecting the pair of isolation protrusions.

4. The magnetic coupling device according to claim 3, wherein the starting angle is 50° or less.

5. The magnetic coupling device according to claim 2, wherein each of the first and second terminal portions is provided at a distance of 5 mm or more from the isolation projection.

6. The magnetic coupling device according to claim 5, wherein each of the first and second terminal portions is arranged in alignment with a virtual parallel line parallel to a virtual straight line connecting the pair of isolation protrusions at the outermost casing of the first coil or the second coil relative to the isolation protrusion.

7. The first bobbin includes a pair of bobbin extensions extending from the groove on both sides, The magnetic coupling device according to claim 1, wherein the distance from the groove to the outermost edge in a predetermined direction of the central portion of each bobbin extension is smaller than the length of the first terminal portion or the second terminal portion.

8. The magnetic coupling device according to claim 7, wherein a second isolation projection is formed in the central portion of the bobbin extension.

9. The magnetic coupling device according to claim 7, wherein the first bobbin is formed such that at least a portion of it bulges outward along the shape of the groove.

10. The magnetic coupling device according to claim 1, wherein the angle θ1 between the last winding of the first coil and the last winding of the second coil facing it is 20 to 100°.

11. The magnetic coupling device according to claim 10, wherein the angle θ2 formed by the first terminal portion and the second terminal portion with respect to the center of the second bobbin is 20 to 100°.

12. The magnetic coupling device according to claim 11, wherein the ratio of the angles (θ2 / θ1) is 0.2 to 5.

13. The first bobbin further includes a third terminal portion and a fourth terminal portion, The magnetic coupling device according to claim 1, wherein each of the first to fourth terminal portions is arranged in each of the quarter-plane regions of the outer casing of the groove portion.

14. The magnetic coupling device according to claim 1, wherein the first extension and the second extension each extend outward from the groove and spread apart from each other at a gradually increasing angle, and are connected to the first terminal and the second terminal.

15. The magnetic coupling device according to claim 1, wherein the first bobbin further includes a guide groove on its outer surface.

16. The guide groove portion further includes a first guide groove portion and a second guide groove portion, The magnetic coupling device according to claim 15, wherein the first extension and the second extension are arranged in the first guide groove and the second guide groove, respectively.

17. The magnetic coupling device according to claim 15, wherein the guide groove is connected to the groove in which the second bobbin is arranged.

18. The magnetic coupling device according to claim 1, wherein the first bobbin includes a radial extension that extends radially from the groove and is provided with the first and second terminal portions, respectively.

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