Magnetic component

Abstract

A magnetic component according to an embodiment includes: a substrate including an upper surface and a lower surface, and a first side surface and a second side surface disposed between the upper surface and the lower surface and facing each other in a first horizontal direction; a core unit disposed on the upper surface of the substrate and including a first core and a second core spaced apart from each other in the first horizontal direction; and a coil unit disposed between the first core and the second core. The substrate includes a concave portion that is concave toward the second side surface from the first side surface.

Description

magnetic components

[0001] The embodiment relates to a magnetic component.

[0002] In general, magnetic components may include inductors and printed circuit boards. Inductors are one of the electronic components applied on printed circuit boards, and due to their electromagnetic properties, they can be applied to resonant circuits, filter circuits, power circuits, etc.

[0003] For example, when an inductor is placed on a circuit board in the form of a DIP (Dual Inline Package), the volume of the magnetic component may increase, and research is being conducted on this.

[0004] The embodiment provides a compact magnetic component.

[0005] A magnetic component according to one embodiment includes a substrate including an upper surface and a lower surface, and a first side surface and a second side surface disposed between the upper surface and the lower surface and facing each other along a first horizontal direction; a core portion including a first core and a second core disposed on the upper surface of the substrate and spaced apart from each other along the first horizontal direction; and a coil portion disposed between the first core and the second core, wherein the substrate may include a concave portion recessed from the first side surface toward the second side surface.

[0006] For example, the recessed portion may include first and second recessed portions spaced apart from each other along the second horizontal direction, and the second horizontal direction may be orthogonal to the first horizontal direction.

[0007] For example, each of the first core and the second core includes first and second outer legs spaced apart from each other along the second horizontal direction; and a middle leg disposed between the first and second outer legs, wherein a vertical length of each of the first and second outer legs is greater than a vertical length of the middle leg, and the first and second outer legs can contact the upper surface of the substrate.

[0008] For example, the coil portion may include one end and the other end, and the one end of the coil portion may include a first part disposed within the first concave portion; and a second part extended from the first part and bent in the second horizontal direction below the lower surface of the substrate, and the other end of the coil portion may include a third part disposed within the second concave portion; and a fourth part extended from the third part and bent in a direction opposite to the second horizontal direction in which the second part extends below the lower surface of the substrate.

[0009] For example, the substrate may include a third side disposed between the first side and the second side; and a fourth side positioned opposite the third side in the second horizontal direction, wherein the second portion may extend to the third side, and the fourth portion may extend to the fourth side.

[0010] For example, the second portion and the first outer leg may overlap in the vertical direction with the substrate therebetween, and the fourth portion and the second outer leg may overlap in the vertical direction with the substrate therebetween.

[0011] For example, each of the second and fourth parts may be arranged in the form of a pad on the lower surface of the substrate.

[0012] For example, the magnetic component may further include a dummy member disposed on the lower surface of the substrate, spaced apart from each of the second and fourth portions.

[0013] For example, the first thickness of the dummy member and the second thickness of each of the second and fourth portions may be the same.

[0014] For example, the first core and the second core each include a third concave portion concave along the vertical direction, the third concave portion being located between the first outer leg and the second outer leg, and the third concave portion can overlap the coil portion along the first horizontal direction.

[0015] A magnetic component according to another embodiment comprises: a substrate; a core portion including an upper core and a lower core arranged opposite to the upper core in a first direction; and a coil portion at least partially accommodated between the upper core and the lower core, wherein the substrate may include a first through hole through which one end of the coil portion passes; and a second through hole through which the other end of the coil portion passes.

[0016] For example, the substrate may include first and second side surfaces positioned opposite to each other in the first direction, and the first and second through holes may both be disposed on one of the first and second side surfaces.

[0017] For example, the upper core and the lower core each include first and second outer legs spaced apart from each other in a second direction intersecting the first direction and extending in a third direction intersecting the first and second directions, respectively; and a middle leg disposed between the first and second outer legs, wherein both sides of each of the first and second outer legs are positioned on opposite sides in the third direction, and among the both sides of each of the first and second outer legs, a side adjacent to the one end and the other end of the coil portion may be disposed in contact with the top surface of the substrate.

[0018] For example, the one end of the coil portion may include a first portion arranged in the first through hole; and a second portion extended by being bent in the second direction from the first portion below the bottom surface of the substrate, and the other end of the coil portion may include a third portion arranged in the second through hole; and a second portion extended by being bent in the opposite direction of the second direction from the third portion below the bottom surface of the substrate.

[0019] For example, the substrate may include a third side disposed between the first side and the second side; and a fourth side positioned opposite the third side in the second direction, wherein the second portion may extend to the third side, and the fourth portion may extend to the fourth side.

[0020] For example, the second part and the first outer leg may overlap in the third direction with the substrate therebetween, and the fourth part and the first outer leg may overlap in the third direction with the substrate therebetween.

[0021] For example, each of the second and fourth parts may be arranged in the form of a pad on the bottom surface of the substrate.

[0022] For example, the magnetic component may further include a dummy member disposed spaced apart from each of the second and fourth portions on the bottom surface of the substrate.

[0023] For example, the first thickness of the dummy member and the second thickness of each of the second and fourth portions may be the same.

[0024] For example, the error between the first thickness of the dummy member and the second thickness of each of the second and fourth portions may be within a predetermined range.

[0025] For example, the first thickness of the dummy member and the second thickness of each of the second and fourth parts may be 0.8 mm to 1.2 mm.

[0026] The magnetic component according to the embodiment can have a compact size by improving the support of the substrate supporting the inductor and minimizing spatial loss by mounting the inductor on the substrate in an SMD type to ensure efficiency.

[0027] Figure 1a shows a partially exploded perspective view of a magnetic component according to an embodiment.

[0028] Figure 1b shows a perspective view of the combined magnetic components shown in Figure 1a.

[0029] Figure 1c shows a bottom view of the magnetic component illustrated in Figure 1a.

[0030] Figure 1d shows a right side view of the magnetic component illustrated in Figure 1a.

[0031] Figure 1e shows a partial front view of the magnetic component illustrated in Figure 1a.

[0032] FIG. 2a shows an exploded perspective view of an embodiment of the inductor illustrated in FIGS. 1a to 1e.

[0033] Fig. 2b shows an assembled perspective view of the inductor illustrated in Fig. 2a.

[0034] Figure 3 shows a bottom view of the substrate illustrated in Figures 1a to 1e.

[0035] The present invention is susceptible to various modifications and embodiments. Specific embodiments are illustrated and described in the drawings. However, this is not intended to limit the present invention to specific embodiments, but rather to encompass all modifications, equivalents, and alternatives falling within the spirit and technical scope of the present invention.

[0036] Terms including ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by these terms. These terms are used solely to distinguish one component from another. For example, without departing from the scope of the present invention, a second component may be referred to as a first component, and similarly, a first component may also be referred to as a second component. The term "and / or" includes a combination of a plurality of related described items or any of a plurality of related described items.

[0037] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0038] In the description of the embodiments, the description that each layer (film), region, pattern or structure is formed "on" or "under" the substrate, each layer (film), region, pad or pattern includes both being formed directly or through the interposition of another layer. The reference to "on" or "under" each layer is explained based on the drawings. In addition, the thickness or size of each layer (film), region, pattern or structure in the drawings may be modified for clarity and convenience of explanation, and therefore does not entirely reflect the actual size.

[0039] The terminology used in this application is only used to describe specific embodiments and is not intended to limit the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, it should be understood that the terms "comprise" or "have" indicate the presence of a feature, number, step, operation, component, part, or combination thereof described in the specification, but do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0040] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Terms defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and will not be interpreted in an idealized or overly formal sense unless explicitly defined herein.

[0041] Hereinafter, embodiments will be described in detail with reference to the attached drawings. Regardless of the drawing symbols, identical or corresponding components will be given the same reference numbers and redundant descriptions thereof will be omitted.

[0042] Additionally, some embodiments are described using a Cartesian coordinate system (x-axis, y-axis, z-axis), and in the Cartesian coordinate system, the x-axis, y-axis, and z-axis depicted in each drawing are orthogonal to each other, but the embodiments are not limited thereto. The x-axis, y-axis, and z-axis may also intersect each other.

[0043] Hereinafter, a magnetic component according to an embodiment is described with reference to the attached drawings.

[0044] FIG. 1a shows a partially exploded perspective view of a magnetic component (100) according to an embodiment, FIG. 1b shows a combined perspective view of the magnetic component (100) shown in FIG. 1a, FIG. 1c shows a bottom view of the magnetic component (100) shown in FIG. 1a, FIG. 1d shows a right side view of the magnetic component (100) shown in FIG. 1a, and FIG. 1e shows a partial front view of the magnetic component (100) shown in FIG. 1a.

[0045] A magnetic component (100) according to one embodiment may include an inductor (or transformer) and a substrate (130). In addition, the magnetic component (100) may or may not further include a dummy member (140).

[0046] Hereinafter, the magnetic component (100) according to the embodiment is described as having an inductor placed on a substrate (130), but the following description can also be applied to a case where a transformer is placed on a substrate (130).

[0047] The inductor may include a core portion (110) and a coil portion (120).

[0048] FIG. 2a shows an exploded perspective view of an embodiment of the inductor shown in FIGS. 1a to 1e, and FIG. 2b shows an assembled perspective view of the inductor shown in FIG. 2a.

[0049] An inductor included in a magnetic component (100) according to an embodiment is described with reference to FIGS. 2A and 2B, but the embodiment is not limited to a specific form of the inductor included in the magnetic component (100).

[0050] The core portion (110) has the characteristics of a magnetic circuit and can act as a path for magnetic flux. The core portion (110) can include a first core (hereinafter referred to as an 'upper core') (112) and a second core (hereinafter referred to as a 'lower core') (114).

[0051] The lower core (114) is disposed opposite to the upper core (112) in the first direction (i.e., the z-axis direction) (or the first horizontal direction) and can be coupled with the upper core (112). The two cores (112, 114) may have shapes that are symmetrical with respect to each other vertically, or may have asymmetrical shapes. However, in the following description, it is assumed that the shapes are symmetrical with respect to each other vertically for the convenience of explanation. That is, the lower core (114) and the upper core (112) are disposed spaced apart from each other along the first horizontal direction.

[0052] Each of the upper core (112) and the lower core (114) may include a body portion in the form of a flat plate and a plurality of leg portions protruding from the body portion in a first direction, i.e., the z-axis direction, and extending along a third direction (e.g., the y-axis direction). The plurality of leg portions may include two outer legs (OL1, OL2) spaced apart from each other along one axial direction (e.g., the second direction, i.e., the x-axis direction) (or, the second horizontal direction) on a plane and extending along the other axial direction (e.g., the y-axis direction), and one middle leg (CL) arranged between the two outer legs (OL1, OL2).

[0053] The vertical length of each of the first and second exopods (OL1, OL2) may be greater than the vertical length of the middle toe (CL).

[0054] When the upper core (112) and the lower core (114) are connected vertically, each of the outer and middle legs of the upper core (112) faces the corresponding outer or middle legs of the lower core (114). At this time, a gap of a predetermined distance (for example, 10 μm to 200 μm, but not necessarily limited thereto) may be formed between at least some of the outer or middle leg pairs that face each other. In the case of FIGS. 1A, 1B, 1D, 1E, and 2B, the gap is illustrated as being '0', but the embodiment is not limited to a specific size of the gap.

[0055] Additionally, each of the upper core (112) and the lower core (114) may include a magnetic material, such as, but not necessarily limited to, iron or ferrite.

[0056] As described above, each of the upper core (112) and the lower core (114) may include first and second outer legs (OL1, OL2) and a middle leg (CL). The first and second outer legs (OL1, OL2) are spaced apart from each other in the x-axis direction, which is a second direction intersecting the first direction, and the middle leg (CL) may be disposed between the first and second outer legs (OL1, OL2).

[0057] The upper core (112) and the lower core (114) each include a third concave portion (hereinafter referred to as a “home”) concave along the vertical direction, and the third concave portion is located between the first outer leg (OL1) and the second outer leg (OL2). In addition, the third concave portion may overlap the coil portion (120) along the first horizontal direction.

[0058] For example, although it is illustrated that a groove (H1) is formed on one side (CS1) of the upper core (112) and no groove is formed on the other side (CS2), and a groove (H2) is formed on one side (CS1) of the lower core (114) and no groove is formed on the other side (CS2), the grooves (H1, H2) may also be formed on the other side (CS2), or may not be formed on either the one side (CS1) or the other side (CS2).

[0059] The coil portion (120) may be arranged so that at least a portion of it is accommodated between the upper core (112) and the lower core (114). As illustrated, the coil portion (120) may include one coil, or, unlike illustrated, may include a plurality of coils stacked in the z-axis direction, which is the first direction.

[0060] In this way, if the coil section (120) includes multiple coils rather than just one coil, the allowable current level can be increased, which may be advantageous when considering the current density of the coil.

[0061] The coil portion (120) may include a winding portion (WP) and end portions (E1, E2). The winding portion (WP) is a portion wound around the middle leg (CL), and at least a portion of the winding portion may be placed between the upper core (112) and the lower core (114) of the core portion (110).

[0062] The two ends (E1, E2) may protrude in a third direction from the winding portion (WP) and may correspond to the starting point and the ending point of the coil portion (120). Here, the third direction is a direction intersecting each of the first direction and the second direction, and may be the y-axis direction. For example, one end (E1) and the other end (E2) of the two ends may protrude in the same direction, that is, the -y-axis direction, as illustrated in FIGS. 2A and 2B, and may correspond to the ending point and the starting point of the coil portion (120). Alternatively, unlike the illustration, one end (E1) and the other end (E2) of the two ends may protrude in the same direction, that is, the +y-axis direction.

[0063] The substrate (130) may be placed below the inductor and may be a printed circuit board (PCB) assembly (e.g., FR4).

[0064] Figure 3 shows a bottom view of the substrate (130) illustrated in Figures 1a to 1e.

[0065] Referring to FIG. 1a and FIG. 3, the substrate (130) may include first to fourth side surfaces (SS1 to SS4), an upper surface (hereinafter referred to as a “top surface”) (TS), and a lower surface (hereinafter referred to as a “bottom surface”) (BS).

[0066] The first side surface (SS1) and the second side surface (SS2) are arranged between the top surface (TS) and the bottom surface (BS) and face each other along the z-axis direction, which is the first direction. In this way, the first side surface (SS1) and the second side surface (SS2) are positioned on opposite sides in the first horizontal direction. The third side surface (SS3) is arranged between the first side surface (SS1) and the second side surface (SS2), and the fourth side surface (SS4) may be positioned on the opposite side of the third side surface (SS3) in the x-axis direction (or the second horizontal direction), which is the second direction intersecting the first direction. The top surface (TS) and the bottom surface (BS) may be positioned on opposite sides in the y-axis direction, which is the third direction.

[0067] The core portion (110) is placed on the top surface (TS) of the substrate (130), and the first and second outer members (OL1, OL2) can be placed in contact with the top surface (TS) of the substrate (130).

[0068] The substrate (130) may include a concave portion (hereinafter referred to as a “through hole”) that is concave from the first side (SS1) toward the second side (SS2). The through hole may include first and second through holes (TH1, TH2) spaced apart along a second horizontal direction, which is the x-axis direction. The second horizontal direction is orthogonal to the first horizontal direction.

[0069] The first through hole (TH1) may be formed so that one end (E1) of the coil portion (120) may pass through it, and the second through hole (TH2) may be formed so that the other end (E2) of the coil portion (120) may pass through it.

[0070] According to an embodiment, the first through hole (TH1) and the second through hole (TH2) may be arranged on any one of the first to fourth side surfaces (SS1 to SS4) of the substrate (130). For example, as illustrated, the first through hole (TH1) and the second through hole (TH2) may be arranged adjacent to each other on the first side surface (SS1) of the substrate (130).

[0071] In the core portion (110) described above, the two sides (OS1, OS2) of each of the first and second outer legs (OL1, OL2) may be positioned on opposite sides in the y-axis direction, which is the third direction. The two ends (E1, E2) of the coil portion (120) may be positioned adjacent to either side of the two sides (OS1, OS2). For example, the two ends (E1, E2) of the coil portion (120) may be positioned adjacent to the first side (OS1) (the part hatched with a grid pattern in FIG. 2b) of the two sides (OS1, OS2) of each of the first and second outer legs (OL1, OL2) rather than the second side (OS2).

[0072] According to an embodiment, among the two sides (OS1, OS2) of each of the first and second extremities (OL1, OL2) located on opposite sides in the third direction, the side adjacent to both one end (E1) and the other end (E2) of the coil portion (120) may be arranged in contact with the top surface (TS) of the substrate (130). For example, when the two ends (E1, E2) of the coil portion (120) are arranged adjacent to the first side (OS1), the first side (OS1) may be arranged in contact with the top surface (TS) of the substrate (130).

[0073] Also, referring to FIGS. 1A, 1B and 1E, one end (E1) of the coil portion (120) may include first and second portions (P1, P2), and the other end (E2) may include third and fourth portions (P3, P4).

[0074] The first portion (P1) is a portion disposed in the first through hole (TH1), and the second portion (P2) is a portion that extends and bends in a second direction (e.g., in the +x-axis direction) from the first portion (P1) below the bottom surface (BS) of the substrate (130). For example, the second portion (P2) may be disposed to extend to the third side surface (SS3).

[0075] The third portion (P3) is a portion disposed in the second through hole (TH2), and the fourth portion (P4) is a portion that is bent and extended in the opposite direction of the second direction (e.g., the -x-axis direction) from the third portion (P3) below the bottom surface (BS) of the substrate (130). For example, the fourth portion (P4) may be disposed to extend to the fourth side surface (SS4).

[0076] In addition, the coil portion (120) may be in a flat shape as illustrated, or may be in a wire shape, unlike the illustrated shape. Regardless of the shape of the coil portion (120), the first part (P1) and the third part (P3) of the opposite ends (E1, E2) of the coil portion (120) in a flat shape or a wire shape may be inserted into the first and second through holes (TH1, TH2), respectively, and then bent to form the second and fourth parts (P2, P4).

[0077] At this time, each of the second and fourth parts (P2, P4) may be pressurized and exist in the form of a pad on the bottom surface (BS) of the substrate (130).

[0078] According to an embodiment, the second part (P2) and the first outer leg (OL1) overlap in the y-axis direction (or vertical direction), which is a third direction intersecting the first and second directions, with the substrate (130) therebetween, and the fourth part (P4) and the second outer leg (OL2) can overlap in the third direction with the substrate (130) therebetween.

[0079] Meanwhile, the dummy member (140) can be placed on the bottom surface (BS) of the substrate (140) spaced apart from each of the second part (P2) and the fourth part (P4) in the z-axis direction, which is the first direction.

[0080] Referring to FIG. 3, the bottom surface (BS) of the substrate (140) may include first to third regions (A1, A2, A3). The first region (A1) may be a region where the second part (P2) is placed, the second region (A2) may be a region where the fourth part (P4) is placed, and the third region (A3) may be a region where the dummy member (140) is placed.

[0081] Referring to FIGS. 1d and 1e, the first thickness (T1) of the dummy member (140) and the second thicknesses (T21, T22) of each of the second and fourth portions (P2, P4) may be the same, or the error between the first thickness (T1) and the second thicknesses (T21, T22) may be within a predetermined range. For example, the first thickness (T1) and the second thickness (T21, T22) may each be 0.8 mm to 1.2 mm, but the embodiment is not limited thereto.

[0082] Hereinafter, the magnetic components of comparative examples and embodiments are described with reference to the attached drawings.

[0083] In the case of the inductor or transformer according to the comparative example, the pin terminal connected to the coil is inserted and placed on the circuit board in the form of a DIP (Dual Inline Package) type. In the case of this DIP type, a hole must be present on the board in the area where the coil pin terminal is inserted. Therefore, if the magnetic component according to the comparative example is applied to a power supply unit (PSU), a space loss in the PSU may occur.

[0084] On the other hand, in the case of the magnetic component (100) according to the embodiment, since one of the two surfaces (OS1, OS2) of each of the outer members (OL1, OL2) is placed in contact with the top surface (TS) of the substrate (130), the support degree of the substrate (130) supporting the inductor can be improved.

[0085] In addition, the second part (P2) of one end (E1) of the coil part (120) and the fourth part (P4) of the other end (E2) can be pressed against the bottom surface (BS) of the substrate (130) so that they themselves function as pads.

[0086] In addition, the flatness of the core part (110) placed on the substrate (130) can be improved by using a dummy member (140). In this way, according to the embodiment, the magnetic component (100) can be implemented compactly by minimizing spatial loss and enhancing efficiency by mounting the inductor or transformer on the substrate (130) in an SMD (Surface Mounting Device) type.

[0087] Although the above has been described focusing on embodiments, these are merely examples and do not limit the present invention. Those skilled in the art to which the present invention pertains will appreciate that various modifications and applications not exemplified above are possible without departing from the essential characteristics of the present embodiment. For example, each component specifically shown in the embodiments can be modified and implemented. In addition, differences related to such modifications and applications should be interpreted as being included within the scope of the present invention defined in the appended claims.

[0088] The mode for carrying out the invention has been sufficiently described in the above-mentioned “Best mode for carrying out the invention.”

[0089] The magnetic components according to the embodiment can be used in instrument transformers, AC calculators, DC-DC converters, step-up transformers, step-down transformers, etc.

Claims

1. A substrate including an upper surface and a lower surface, and a first side surface and a second side surface disposed between the upper surface and the lower surface and facing each other along a first horizontal direction; A core portion including a first core and a second core arranged on the upper surface of the substrate and spaced apart from each other along the first horizontal direction; and including a coil portion disposed between the first core and the second core, The above substrate is a magnetic component including a concave portion that is concave from the first side toward the second side.

2. In paragraph 1, The above concave portion includes first and second concave portions spaced apart from each other along the second horizontal direction, The above second horizontal direction is a magnetic component orthogonal to the above first horizontal direction.

3. In paragraph 2, Each of the first core and the second core First and second extremities spaced apart from each other along the second horizontal direction; and Including a middle foot positioned between the first and second outer feet, The vertical length of each of the first and second extremities is greater than the vertical length of the middle extremity, The first and second extremities are magnetic components in contact with the upper surface of the substrate.

4. In paragraph 3, The above coil portion includes one end and the other end, The above one end of the above coil part A first part disposed within the first concave portion; and A second portion extending from the first portion to the second horizontal direction below the lower surface of the substrate, The other end of the above coil portion a third part disposed within the second concave portion; and A magnetic component including a fourth portion extending from the third portion to the second horizontal direction and bent in the opposite direction from the second portion extending below the lower surface of the substrate.

5. In paragraph 4, The above substrate is a third side disposed between the first side and the second side; and Including a fourth side located opposite the third side in the second horizontal direction, The second portion extends to the third side, The fourth part is a magnetic component extending to the fourth side.

6. In paragraph 5, The second part and the first outer layer overlap in the vertical direction with the substrate interposed therebetween, A magnetic component in which the fourth part and the second outer member overlap in the vertical direction with the substrate interposed therebetween.

7. In paragraph 4, Each of the second and fourth parts is a magnetic component arranged in the form of a pad on the lower surface of the substrate.

8. In paragraph 7, A magnetic component further comprising a dummy member disposed spaced apart from each of the second and fourth portions on the lower surface of the substrate.

9. In paragraph 8, A magnetic component in which the first thickness of the dummy member and the second thickness of each of the second and fourth parts are the same.

10. In paragraph 3, The first core and the second core each include a third concave portion concave along the vertical direction, The third concave portion is located between the first outer leg and the second outer leg, The third concave portion is a magnetic component that overlaps the coil portion along the first horizontal direction.

Images