Magnetic component

Abstract

The present invention relates to a magnetic component and, more specifically, to a magnetic component comprising: a lower core; an upper core disposed on the lower core; and a coil part disposed between the upper core and the lower core, wherein at least one of the upper core or the lower core includes a first region having a first thickness and a second region having a second thickness different from the first thickness. In the magnetic component according to the present invention, the magnetic flux saturation of a core can be reduced to reduce the heat generation of the core itself and improve heat dissipation performance. In addition, the flow of a cooling gas is impeded by a single layer of an auxiliary core unit such that heat exchange time is increased, and thus cooling efficiency may be improved.

Description

magnetic components

[0001] The present invention relates to a magnetic component.

[0002] The power supply of electronic devices is equipped with various coil components such as transformers and line filters.

[0003] Transformers can be incorporated into electronic devices for a variety of purposes. For example, they can be used to transfer energy from one circuit to another. Transformers can also be used to change the magnitude of voltage, either stepping up or stepping down. Furthermore, because transformers only provide inductive coupling between the primary and secondary windings and no direct DC path, they can be used to block DC and pass AC, or to provide insulation between two circuits. Research is ongoing to improve the performance of these transformers.

[0004] The technical problem to be solved by the present invention is to provide a magnetic component having a surface cooling structure with improved cooling efficiency.

[0005] A magnetic component according to the present invention for solving the above technical problem comprises: a lower core; an upper core disposed on the lower core; and a coil portion disposed between the upper core and the lower core; and at least one of the upper core or the lower core may include a first region having a first thickness and a second region having a second thickness different from the first thickness.

[0006] In one or more embodiments, either the first region or the second region may be deposited to a predetermined height on the core surface or may be formed integrally to increase the thickness to form an auxiliary core portion.

[0007] In one or more embodiments, the auxiliary core portion may form a layer that interferes with the main flow of cooling gas.

[0008] In one or more embodiments, the layer may be formed to have a diagonal inclination angle passing through the center of the core portion.

[0009] In one or more embodiments, the diagonal direction may be the direction in which the busbars are connected.

[0010] In one or more embodiments, the inclination angle (AG) may be 0° ≤ AG ≤ 60° with respect to a virtual line extending from the center of the core portion in the direction of the core portion's single width.

[0011] In one or more embodiments, the diagonal direction of the fault layer can be formed symmetrically or asymmetrically with respect to the upper and lower cores.

[0012] In one or more embodiments, the auxiliary core section may form an orifice groove in the main flow direction of the cooling gas.

[0013] In one or more embodiments, the orifice groove may have a shape in which the inlet portion of the cooling gas is wide and gradually narrows toward the outlet portion.

[0014] In one or more embodiments, the auxiliary core portion may be formed in a rear region of the core portion in the main flow direction of the cooling gas.

[0015] In one or more embodiments, an airfoil may be formed in the front region of the core portion to induce a drop of cooling gas.

[0016] In one or more embodiments, the airfoil may be formed at the front edge where the core portion begins.

[0017] In one or more embodiments, an airfoil may be formed in the latter region of the core section to induce a drop in cooling gas.

[0018] In one or more embodiments, the airfoil may be formed at a single-layer corner where the auxiliary core portion begins.

[0019] In one or more embodiments, the auxiliary core portion may be formed in a separate form.

[0020] In one or more embodiments, the auxiliary core section may form an orifice groove in the main flow direction of the cooling gas.

[0021] In one or more embodiments, the orifice groove may have a shape in which the inlet portion of the cooling gas is wide and gradually narrows toward the outlet portion.

[0022] In one or more embodiments, an adhesive member may be placed between the auxiliary core portion and the core portion.

[0023] In one or more embodiments, the second thickness (T2) may be formed thicker than the first thickness (T1).

[0024] The magnetic component according to the present invention can reduce heat generation of the core itself by alleviating magnetic flux saturation of the core.

[0025] The magnetic component according to the present invention can also improve heat dissipation performance.

[0026] The magnetic component according to the present invention also has improved cooling efficiency because the heat exchange time is increased by blocking the flow of cooling gas by a single layer of the auxiliary core portion.

[0027] Figure 1 is a front perspective view of a transformer according to one embodiment of the present invention.

[0028] Figure 2 is a rear perspective view of the transformer illustrated in Figure 1.

[0029] Fig. 3 is a front perspective view of the transformer illustrated in Fig. 1 with the core removed.

[0030] Fig. 4a is a front perspective view of the transformer illustrated in Fig. 1 with the coil section removed, and is a separated perspective view of the upper core and lower core.

[0031] Figure 4b is an enlarged cross-sectional view of the upper core of Figure 4a.

[0032] Fig. 5a is an example of the transformer of Fig. 4a in which the auxiliary core section is separated.

[0033] Fig. 5b is a cross-sectional view of one embodiment of joining the auxiliary core part of Fig. 5a to the core part using an adhesive member.

[0034] Figures 6, 7 and 8 are examples of deformations of an auxiliary core section according to one embodiment of the present invention.

[0035] Figure 9 is a plan view showing an orifice groove formed in an auxiliary core section according to one embodiment of the present invention.

[0036] Fig. 10 is a perspective view of a core portion formed with an airfoil according to one embodiment of the present invention.

[0037] Figures 11a and 11b are a perspective view and a plan view of the first coil section illustrated in Figure 1.

[0038] Figures 12a and 12b are a perspective view and a plan view of the inner coil section shown in Figure 1.

[0039] Figures 13a and 13b are a perspective view and a plan view of the outer coil portion illustrated in Figure 1.

[0040] Figures 14a and 14b are schematic diagrams of a power supply device according to one embodiment and simulation drawings for explaining the cooling effect of a transformer.

[0041] Figures 15 and 16 are diagrams showing examples of the configuration of a power supply device according to the arrangement of peripheral components in another embodiment.

[0042] Figures 17a to 17c are simulation drawings showing changes in the surface temperature of a magnetic component according to the inclination angle deformation of a single layer of an auxiliary core section according to one embodiment.

[0043] Fig. 18 is a diagram showing the surface temperature values ​​of a magnetic component measured according to the inclination angle deformation of a single layer of an auxiliary core section according to an embodiment.

[0044] The advantages and features of the present invention, and the methods for achieving them, will become clearer with reference to the embodiments described in detail below together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms. These embodiments are provided only to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims. Like reference numerals designate like elements throughout the specification.

[0045] “And / or” includes each and every combination of one or more of the items mentioned.

[0046] The terminology used herein is for the purpose of describing embodiments only and is not intended to limit the present invention. In this specification, the singular also includes the plural unless specifically stated otherwise. As used herein, the terms "comprises" and / or "comprising" do not exclude the presence or addition of one or more other components, steps, operations, and / or elements mentioned.

[0047] Additionally, throughout the specification, when a part is said to be "connected" to another part, this includes not only cases where it is "directly connected" but also cases where it is "indirectly" or "electrically connected" with other members or components in between.

[0048] Additionally, throughout the specification, 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 criteria for being on / over or under / under each layer are explained based on the drawings.

[0049] Additionally, expressions such as 'first, second', etc. are used only to distinguish between multiple components, and do not limit the order or other characteristics between the components.

[0050] In addition, the flowcharts illustrated in the drawings are merely exemplary sequences for obtaining the most desirable results in carrying out the present invention, and it is obvious that other steps may be added or some steps may be deleted.

[0051] Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used in their common sense to those of ordinary skill in the art to which the present invention pertains. Furthermore, terms defined in commonly used dictionaries are not to be interpreted ideally or excessively unless explicitly and specifically defined otherwise.

[0052] Hereinafter, the present invention will be described with reference to the attached drawings. Regardless of the drawing numbers, identical or corresponding components are given the same reference numbers, and redundant descriptions thereof may be omitted.

[0053] In addition, although some embodiments are described using a Cartesian coordinate system (x-axis, y-axis, z-axis), the x-axis, y-axis, and z-axis are not necessarily orthogonal to each other and may be described as intersecting each other as needed. Hereinafter, for convenience of explanation, the x-axis direction is referred to as the first direction, the y-axis direction is referred to as the second direction, and the z-axis direction is referred to as the third direction, but this does not necessarily mean the x-axis, y-axis, and z-axis, and is merely an expression to distinguish different directions.

[0054] The present invention relates to a magnetic component having a surface cooling structure with improved cooling efficiency, and more particularly, to a technology for improving the cooling efficiency of a transformer. Hereinafter, the magnetic component will be referred to as a transformer.

[0055] FIG. 1 is a front perspective view of a transformer (100) according to an embodiment of the present invention, FIG. 2 is a rear perspective view of the transformer (100) illustrated in FIG. 1, and FIG. 3 is a front perspective view of the transformer (100) illustrated in FIG. 1 with the core portion (110) removed.

[0056] Referring to FIGS. 1 to 3, a transformer (100) according to one embodiment of the present invention may include a lower core (114), an upper core (112) disposed on the lower core (114), and a coil portion disposed between the upper core (112) and the lower core (114).

[0057] In a transformer (100) like this, high current flows through the coil section, generating high temperature heat. In particular, as the thickness of the core section (110) is gradually decreasing due to miniaturization and slimming of the transformer (100), heat generation in the core section (110) may be accelerated under conditions of medium or higher load.

[0058] Accordingly, the present invention proposes a cooling technology that can reduce its own heat generation by alleviating the magnetic flux saturation of the core part (110) by adding an auxiliary core part (116) to the core part (110), and can also contribute to cooling the peripheral components of the transformer (100).

[0059] The cooling technology according to the present invention can be applied to a transformer (100) installed in a server power supply unit (PSU) that uses a fan cooling method.

[0060] At this time, the transformer (100) can be surface-cooled through an air path in which cooling gas moves between a narrow gap and the inner wall of the case of the server power supply unit.

[0061] Hereinafter, the configuration of a core portion (110) according to one embodiment of the present invention will be described with reference to FIGS. 4a to 10.

[0062] FIG. 4a is a front perspective view of the transformer (100) illustrated in FIG. 1 with the coil removed, and is a separated perspective view of the upper core (112) and the lower core (114), FIG. 4b is an enlarged cross-sectional view of the main part of the upper core (112) of FIG. 4a, FIG. 5a shows an embodiment in which the auxiliary core part (116) is separated from the transformer (100) of FIG. 4a, and FIG. 5b is a cross-sectional view of an embodiment in which the auxiliary core part (116) of FIG. 5a is joined to the core part (110) using an adhesive member (117), FIG. 6, FIG. 7, and FIG. 8 are examples of modifications of the auxiliary core part (116) according to an embodiment of the present invention, FIG. 9 is a plan view in which an orifice groove (116B) is formed in the auxiliary core part (116) according to an embodiment of the present invention, and FIG. 10 is a cross-sectional view of an embodiment of the present invention. This is a perspective view of a core section (110) in which an airfoil (118) is formed.

[0063] The core portion (110) above has the characteristics of a magnetic circuit and can act as a path for magnetic flux. The core portion (110) can include an upper core (112) and a lower core (114). Since the upper core (112) and the lower core (114) illustrated in FIG. 4 have the same appearance, the following description of the lower core (114) can also be applied to the upper core (112).

[0064] The lower core (114) is arranged to face the upper core (112) in a third direction, which is perpendicular to the upper core (112), and can be combined 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 asymmetric shapes. However, in the description below, it is assumed that they have vertically symmetrical shapes for the convenience of explanation.

[0065] Each of the upper core (112) and the lower core (114) may include a body portion (BO) in the form of a flat plate and a plurality of leg portions protruding in a third direction from the body portion (BO) and extending along a predetermined direction. The plurality of leg portions may include two outer legs (OL1, OL2) that are spaced apart from each other along a uniaxial direction (e.g., a second direction) on a plane and extending along an axial direction (e.g., a first direction), and one intermediate leg (CL) that is arranged between the two outer legs (OL1, OL2). In this way, the two first and second outer legs (OL1, OL2) are spaced apart from each other in the second direction, and the intermediate leg (CL) may be arranged between the first and second outer legs (OL1, OL2).

[0066] 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. 1 and 2, the gap is illustrated as being '0', but one embodiment is not limited to a specific size of the gap.

[0067] 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.

[0068] According to one embodiment of the present invention, at least one of the upper core (112) or the lower core (114) may include a first region (A1) having a first thickness (T1) and a second region (A2) having a second thickness (T2) different from the first thickness (T1).

[0069] At this time, the first region (A1) and the second region (A2) may be formed in the body portion (BO). Therefore, the first thickness (T1) and the second thickness (T2) may be thicknesses that include the thickness of the body portion (BO).

[0070] Additionally, either the first region (A1) or the second region (A2) can be formed to have different thicknesses by depositing a certain height on the core surface or forming an auxiliary core portion (116) by increasing the thickness as an integral part.

[0071] At this time, the second thickness (T2) can be formed thicker than the first thickness (T1).

[0072] The auxiliary core section (116) may be formed of the same material as the upper core (112) and lower core (114), or may be formed of another material with excellent thermal conductivity.

[0073] Additionally, the auxiliary core portion (116) may form a layer (116A) that interferes with the main flow of the cooling gas. The layer (116A) may be formed in the form of a plane perpendicular to the surface of the body portion (BO). Additionally, the layer (116A) may be formed to have an oblique inclination angle (AG) passing through the center of the core portion.

[0074] For example, the upper core (112) and the body (BO) of the lower core (114) of the core section are saturated with magnetic flux in a band shape of a certain radius in the circumferential direction based on the center, and an inclination angle (AG) can be formed so that the single layer (116A) passes diagonally through the radius where the magnetic flux saturation occurs. At this time, the radius where the magnetic flux saturation occurs may be the radius of the coil section.

[0075] The above diagonal direction may be the direction in which the bus bar (T1) is connected. For example, the transformer (100) according to the present invention may have a bus bar (300) connected to one side. The bus bar (300) may be connected to a coil section, which will be described later.

[0076] The above inclination angle (AG) can be formed in the range of 0°≤ AG ≤ 60° with respect to a virtual line extending from the center of the core portion (110) in the direction of the single width of the core portion (110).

[0077] Fig. 6 illustrates an example of forming the inclination angle (AG) as 0°, Fig. 7 illustrates an example of forming the inclination angle (AG) as 40°, and Fig. 8 illustrates an example of forming the inclination angle (AG) between 40° and 60°.

[0078] The diagonal direction of such a fault (116A) can be formed in a symmetrical or asymmetrical form in the upper and lower cores, respectively.

[0079] According to one embodiment of the present invention, an orifice groove (116B) may be formed in the auxiliary core part (116). Referring to FIG. 9, the orifice groove (116B) may be formed along the main flow direction in which the cooling gas of the auxiliary core part (116) moves, and the orifice groove (116B) may have a shape in which the entrance portion where the cooling gas enters is wide and gradually narrows toward the discharge portion.

[0080] Such an orifice groove (116B) utilizes the fact that the cooling gas passing through a narrow passage becomes faster due to the decompression effect, and since the surrounding cooling gas is sucked into the orifice groove (116B) where the decompression effect occurs, the heat dissipation effect on the surface of the core part (110) can be improved.

[0081] The auxiliary core section (116) can be formed in the latter part of the core section (110) in the main flow direction of the cooling gas.

[0082] The auxiliary core part (116) formed in the latter half of the core part (110) can play a role in expanding the heat dissipation area of ​​the core part (110) and inducing the flow of cooling gas around the auxiliary core part (116) to form a vortex.

[0083] For example, a larger heat dissipation area can be secured in proportion to the thickness of the auxiliary core part (116), and the flow of cooling gas flowing along the surface of the core part (110) collides with a single layer (116A) of the auxiliary core part (116) to form a refracted air current that is refracted in a vertical or horizontal direction, and the refracted air current collides with the main flow of cooling gas again to form a vortex. The vortex at this time can improve heat exchange efficiency by allowing the cooling gas to contact the surface of the core part (110) for a longer period of time.

[0084] According to one embodiment of the present invention, an airfoil (118) that induces the descent of cooling gas may be formed in the front portion of the core portion (110).

[0085] Referring to Fig. 10, the airfoil (118) may be formed into an airfoil structure such as an airplane wing. The airfoil structure according to one embodiment of the present invention utilizes the principle of an airplane wing generating lift, and the cooling gas passing through the upper surface of the airfoil (118) has a high-velocity flow along the curve along with the downward airflow, thereby inducing the cooling gas to pass through in close contact with the surface of the core portion (110). This structure, together with the single-layer (116A) structure of the auxiliary core portion (116), contributes to improving the surface cooling efficiency of the core portion (110).

[0086] At this time, the downward airflow generated while passing through the airfoil (118) may collide with the single layer of the auxiliary coil section and become vortexed.

[0087] A plurality of such airfoils (118) can be installed along the direction of cooling gas flow in the core section (110).

[0088] In Fig. 10, only an example is shown in which the airfoil (118) is formed at the front edge where the core portion (110) begins, but this is only an exemplary form and is not limited to the form shown.

[0089] For example, the airfoil (118) may be formed at the edge of the single layer where the auxiliary core portion (116) begins, or may be formed along the upper surface of the auxiliary core portion (116).

[0090] According to one embodiment of the present invention, the auxiliary core portion (116) may be formed in a separate form.

[0091] As shown in Fig. 5, the detachable auxiliary core part (116) can be provided in a form attached to the upper core (112) and lower core (114) of the transformer. When the detachable auxiliary core part (116) is applied, it is possible to improve the cooling performance of an existing transformer that is installed and in use, and it can provide the advantage of being able to be applied without changing the core part mold of an existing production line.

[0092] The above auxiliary core part (116) can form an orifice groove (116B) in the main flow direction of the cooling gas. The above orifice groove (116B) can have a shape in which the inlet portion of the cooling gas is wide and gradually narrows toward the outlet portion.

[0093] By placing an adhesive member (117) between the auxiliary core part (116) and the core part (110), the two sides can be joined together. The adhesive member (117) may be an adhesive material made of a conductive material.

[0094] Hereinafter, the configuration of a coil unit according to an embodiment of the present invention will be described with reference to FIGS. 11a to 13b.

[0095] FIGS. 11a and 11b show a perspective view and a plan view, respectively, of the first coil portion (120) illustrated in FIG. 1, FIGS. 12a and 12b show a perspective view and a plan view, respectively, of the inner coil portion (130) illustrated in FIG. 1, and FIGS. 13a and 13b show a perspective view and a plan view, respectively, of the outer coil portion (140) illustrated in FIG. 1.

[0096] According to one embodiment of the present invention, at least a portion of the coil portion can be accommodated between the upper core (112) and the lower core (114).

[0097] Hereinafter, the coil section is described in detail as follows.

[0098] The coil portion may include a first coil portion (120) and a second coil portion (130, 140).

[0099] The first coil portion (120) may be a coil in a wound form, and at least a portion of the coil may be disposed on the inner side of the core portion (110). The first coil portion (120) may be disposed to surround the intermediate leg (CL). At this time, the first coil portion (120) may be formed at the center thereof (120), and may include a through hole (TH) in which the second coil portion (130) and the inner bobbin (IB) are disposed and through which the intermediate leg (CL) passes.

[0100] Referring to FIG. 11b, the outer side (120OS) of the first coil portion (120) may include first to fourth outer sides (SS1, SS2, SS3, SS4).

[0101] The first outer side (SS1) and the second outer side (SS2) are located on opposite sides in the first direction.

[0102] The third outer side (SS3) is positioned between the first outer side (SS1) and the second outer side (SS2), and the fourth outer side (SS4) is positioned on the opposite side of the third outer side (SS3) in a second direction intersecting the first direction.

[0103] Meanwhile, the second coil portion (130, 140) may be disposed at least partially on the inner side of the core portion (110). That is, the second coil portion (130, 140) may be disposed at least partially on the inner side (120IS) and outer side (120OS) of the first coil portion (120).

[0104] The second coil portion may include an inner coil portion (130) and an outer coil portion (140).

[0105] The inner coil portion (130) may be arranged on at least a portion of the inner side (120IS) of the first coil portion (120), and the outer coil portion (140) may be arranged on at least a portion of the outer side (120OS) of the first coil portion (120).

[0106] The inner coil part (130) may include an inner upper coil part (132) and an inner lower coil part (134) that are arranged vertically with each other. The inner upper coil part (132) may be arranged above the inner side (120IS) of the first coil part (120), and the inner lower coil part (134) may be arranged below the inner side (120IS) of the first coil part (120).

[0107] The inner upper coil part (132) and the inner lower coil part (134) may have a shape symmetrical in a third direction, which is a vertical direction. The inner upper coil part (132) may include a first upper body (hereinafter referred to as the 'first body') (B1U) and a first upper terminal (hereinafter referred to as the 'first terminal') (PI1U, P12U). The first body (BIU) may be arranged on the upper side of the inner side (120IS) of the first coil part (120). The first terminal (PI1U, PI2U) may protrude in a positive first direction intersecting the vertical direction from an upper end (US1) of the first body (BIU).

[0108] The inner upper coil portion (132) may extend in a first direction intersecting the third direction and may include a first inner upper terminal (PI1U) formed at one end of the inner upper coil portion (132) and a second inner upper terminal (PI2U) formed at the other end of the inner upper coil portion (132).

[0109] The inner lower coil portion (134) may include a first lower body (hereinafter referred to as the “first body”) (B1L) and a first lower terminal (hereinafter referred to as the “first terminal”) (PI1L, P12L). The first body (BIL) may be arranged on the lower side of the inner side (120IS) of the first coil portion (120). The first terminal (PI1L, PI2L) may protrude in a positive first direction intersecting the vertical direction from an upper end of the first body (BIL).

[0110] The inner lower coil portion (134) may extend in the first direction and include a first inner lower terminal (PI1L) formed at one end of the inner lower coil portion (134) and a second inner lower terminal (PI2L) formed at the other end of the inner lower coil portion (134).

[0111] As described above, the first terminal (PI1U, PI2U, PI1L, PI2L) may be bent from the inside of the core portion (110) and positioned to protrude from the outside of the core portion (110).

[0112] In addition, the inner coil part (130) may include guide protrusions (G1U, G2U) extending horizontally so as to overlap vertically with the upper surface of the first coil part (120). In this way, the first terminals (PI1U, PI2U, PI1L, PI2L) may be formed at one end of the inner coil part (130), and the guide protrusions (G1U, G2U) may be formed to extend in an area between one end and the other end of the inner coil part (130). That is, each of the inner upper coil part (132) and the inner lower coil part (134) may further include guide protrusions (G1U, G2U).

[0113] For example, as illustrated, the guide protrusion (GIU, G2U) may be positioned above the first coil portion (120) by protruding in the negative first direction from the upper end (US2) opposite to the upper end (US1) of the first body (B1U).

[0114] In one embodiment, by arranging the guide protrusions (G1U, G2U), the first coil portion (120) can be prevented from vertically deviating from its original position. That is, the guide protrusions (G1U, G2U) (and / or G1L, G2L) serve to guide the first coil portion (120) to be positioned in its original position.

[0115] The protruding length (L1) of the first terminal (PI1U, PI2U) (or PI1L, PI2L) may be longer than the protruding length (L24) of the guide protrusion (G1U, G2U) (or G1L, G2L).

[0116] Meanwhile, the outer coil portion (140) may include an outer upper coil portion (142) and an outer lower coil portion (144) arranged vertically with each other.

[0117] The outer upper coil portion (142) may be positioned above at least a portion of the outer side (120OS) of the first coil portion (120). The outer lower coil portion (144) may be positioned below at least a portion of the outer side (120OS) of the first coil portion (120).

[0118] The outer upper coil portion (142) and the outer lower coil portion (144) may have a shape that is symmetrical in the third direction, which is the vertical direction.

[0119] The outer upper coil portion (142) may include a second upper body (hereinafter referred to as the 'second body') (B2U), a second upper terminal (hereinafter referred to as the 'second terminal') (PO1U, PO2U), and an upper bridge (PO3U).

[0120] The second body (B2U) may be arranged on at least a portion of the outer side (120OS) of the first coil portion (120). The second terminals (PO1U, PO2U) may protrude in the positive first direction from the second body (B2U). The upper bridge (PO3U) may be in the shape of a bar connecting the second terminals (PO1U, PO2U).

[0121] The outer upper coil portion (142) may include a first outer upper terminal (PO1U) formed at one end of the outer upper coil portion (142) extending in the first direction, a second outer upper terminal (PO2U) formed at the other end of the outer upper coil portion (142), and an upper bridge (PO3U) connecting the first outer upper terminal (PO1U) and the second outer upper terminal (PO2U).

[0122] Likewise, the outer lower coil portion (144) may include a second lower body (hereinafter referred to as the 'second body') (B2L), a second lower terminal (hereinafter referred to as the 'second terminal') (PO1L, PO2L), and a lower bridge (PO3L).

[0123] The second body (B2L) may be arranged on at least a portion of the outer side (120OS) of the first coil portion (120). The second terminals (PO1L, PO2L) may protrude in the positive first direction from the second body (B2L). The lower bridge (PO3L) may have a bar shape connecting the second terminals (PO1L, PO2L).

[0124] The outer lower coil portion (144) may include a first outer lower terminal (PO1L) formed at one end of the outer lower coil portion (144) extending in the first direction, a second outer lower terminal (PO2L) formed at the other end of the outer lower coil portion (144), and an upper bridge (PO3L) connecting the first outer lower terminal (PO1L) and the second outer lower terminal (PO2L).

[0125] One end and the other end of each of the inner upper coil portion (132), the inner lower coil portion (134), the outer upper coil portion (142), and the outer lower coil portion (144) may be formed to extend in the first direction. That is, the first terminals (PI1U, PI2U, PI1L, PI2L) and the second terminals (PO1U, PO2U, PO1L, PO2L) may all be formed to extend equally in the first direction.

[0126] Additionally, when viewed in a second direction perpendicular to the first and third directions, the positions of the first outer upper terminal (PO1U), the second outer upper terminal (PO2U), the first outer lower terminal (PO1L), and the second outer lower terminal (PO2L) may be arranged between the first inner upper terminal (PI1U) and the first inner lower terminal (PI1L).

[0127] As described above, the coil portion according to one embodiment of the present invention may include a plurality of terminals protruding in the first direction.

[0128] For example, when the transformer (100) operates in a sensor tab structure, the second terminal (PO1U, PO2U) and the first terminal (PI1L, PI2L) may operate as a pair, and the first terminal (PI1U, PI2U) and the second terminal (PO1L, PO2L) may operate as a pair.

[0129] The inner upper coil part (132) and the outer lower coil part (144) are electrically connected, and the inner lower coil part (134) and the outer upper coil part (142) can be electrically connected.

[0130] Additionally, it may be arranged so that more than 50% of the outer surface area of ​​the outer coil portion (140) is exposed to the outside of the core portion (110).

[0131] Additionally, the second body (B2U, B2L) can cover the second to fourth outer surfaces (SS2, SS3, SS4) of the first coil portion (120) and expose the first outer surface (SS1).

[0132] At least one of the first coil portion (120) or the second coil portion (130, 140) described above may be replaced with a Litz wire or a copper plate coil, but is not necessarily limited thereto.

[0133] Each of the inner coil portion (130) and the outer coil portion (140) may be a plate-shaped coil.

[0134] The transformer (100) may further include an inner bobbin (or bobbin) (IB). The inner bobbin (IB) may be positioned inside (or inside) the inner coil section (130). The inner bobbin (IB) serves to fix the position of the inner coil section (130).

[0135] Hereinafter, a power supply device (200) according to an embodiment of the present invention will be briefly examined with reference to the attached drawings.

[0136] Figures 14a and 14b are schematic diagrams of a power supply device (200) according to one embodiment and simulation drawings for explaining the cooling effect of a transformer. To aid understanding, Figure 14b only shows the transformer (100) and the printed circuit board (210).

[0137] A power supply device (200) according to one embodiment of the present invention may include a printed circuit board (210), a bus bar (230), a rectifier (242), and a transformer (100). In addition, the power supply device (200) may further include a fan (220). In addition, the power supply device (200) may further include an inductor (260). In order to facilitate understanding of a portion that is not visible because it is covered by the bus bar (230) in FIG. 14A, it is indicated with a dotted line.

[0138] The printed circuit board (210) and inductor (260) illustrated in Fig. 14a are related to known technology, and the present invention is not limited to the specific configuration of these (210, 260), so a detailed description thereof is omitted.

[0139] The bus bar (230) can be placed on top of the transformer (100) and the inductor (260). The bus bar (230) can be electrically connected to the transformer (100) and the inductor (260).

[0140] For example, the first terminal (PI1U, PI2U, PI1L, PI2L) and the second terminal (PO1U, PO2U, PO1L, PO2L) described above can be electrically connected to a bus bar (230). Through the bus bar (230), the terminals can be connected to each other or to an external substrate or separate electrical elements.

[0141] The rectifier (242) may be placed on the side of the transformer (100). The rectifier (242) may serve to rectify the alternating current output through the second coil unit (130, 140) of the transformer (100), and may be, for example, a synchronous rectifier, but is not necessarily limited thereto.

[0142] When the fan (220) operates, a large amount of air may flow between the printed circuit board (210) and the transformer (250). In the present invention, taking this into consideration, the second body (B2) of the outer coil part (140) disposed on the second outer surface (SS2) is disposed to face the printed circuit board (210) so that the outer coil part (140) is exposed to the outside of the core part (110) by more than 50%. In this case, the second body (B2) of the outer coil part (140) may be exposed to a path through which a large amount of air flows, so that the surface of the second coil part (140) through which a large current flows is exposed to the air, thereby maximizing the cooling method of the fan (220) and improving the heat dissipation characteristics.

[0143] In addition, according to one embodiment of the present invention, since the outer coil part (140) can play a role in wrapping the first coil part (120) to maintain the overall shape, an outer bobbin is not required, thereby reducing the unit cost of the transformer.

[0144] In addition, according to one embodiment of the present invention, since the inner and outer coil parts (130, 140) are respectively arranged on the inner side (120IS) and the outer side (120OS) of the first coil part (120), the coupling between the first coil part (120) and the second coil part (130, 140) is increased, thereby reducing the leakage inductance of the transformer (100).

[0145] In addition, in one embodiment of the present invention, the inner coil part (130) and the outer coil part (140) are arranged symmetrically vertically, respectively. That is, when the first terminals (PI1U, PI1L, PI2U, PI2L) are arranged and the second terminals (PO1U, PO2U, PO1L, PO2L) are arranged as shown, the components can be driven symmetrically during operation, thereby improving component balance (so that the magnetic flux is not concentrated in one area).

[0146] The portion covering the second outer surface (SS2) of the second body (B2: B2U, B2L) can be placed facing a bus bar or printed circuit board (210) for electrical connection.

[0147] The busbar (300) can be placed on top of the transformer (100) and the inductor, and can be electrically connected to the transformer (100) and the inductor.

[0148] The rectifier may be placed on the side of the transformer (100). The rectifier may serve to rectify the alternating current output through the secondary coil of the transformer (100), and may be, for example, a synchronous rectifier, but is not necessarily limited thereto.

[0149] The bus bar (300) can form a plurality of through holes so that the second terminal (PO1U, PO2U) and the first terminal (PI1L, PI2L) can pass through and be electrically connected.

[0150] At this time, as shown in Fig. 14b, the bus bar (300) is spaced apart from the core portion (110) of the transformer (100) in the first direction, and the spaced apart space can form a path through which a cooling gas (e.g., air) passes.

[0151] At this time, the first terminal (PI1U, PI2U) and the second terminal (PO1L, PO2L) are connected to the upper and lower bridges (PO3U, PO3L) to form a “ㄷ” shape so that they are electrically connected to the bus bar (300) but do not penetrate through the bus bar and a certain distance is maintained between them and the core part (110).

[0152] The width of the euro in the first direction may be greater than 0 and less than or equal to 3.5 mm, but the embodiment is not limited thereto. That is, the bus bar (300) may be arranged to be spaced apart from the core portion (110) in the first direction by a distance greater than 0 and less than or equal to 3.5 mm.

[0153] According to one embodiment of the present invention, a space is provided between the bus bar (300) and the transformer (100), and cooling gas is allowed to enter and exit through this space, thereby cooling the transformer (100) and the bus bar (300) more quickly.

[0154] Figure 14b is a simulation drawing to explain the cooling effect at this time. The center of the transformer is cut diagonally, so air moves along the diagonal surface, demonstrating that this can effectively reduce the temperature of the coil.

[0155] Figures 15 and 16 are exemplary configuration diagrams of a power supply device according to a peripheral component arrangement form according to another embodiment of the present invention. As shown in Figures 15 and 16, an inductor (260A, 260B) may be positioned between the magnetic component (100) and the fan (220) of the present invention.

[0156] At this time, the inductor (260A) of Fig. 15 is a hexahedral inductor, and the inductor (260B) of Fig. 16 is an example in which a cylindrical inductor is arranged.

[0157] The magnetic component (100) according to the present invention can provide a single-layer structure for improving cooling efficiency, and can smoothly induce the flow of air paths together with the appropriate shape and arrangement of surrounding components.

[0158] FIGS. 17a to 17c are simulation drawings showing changes in the surface temperature of a magnetic component according to the inclination angle deformation of a single layer of an auxiliary core part according to one embodiment of the present invention, and FIG. 18 is a diagram measuring the surface temperature value of a magnetic component according to the inclination angle deformation of a single layer of an auxiliary core part.

[0159] Figure 17a shows the temperature distribution when the inclination angle (AG) of the fault is formed at 0°, Figure 17b shows the temperature distribution when the inclination angle (AG) of the fault is formed at 40°, and Figure 17c shows the temperature distribution when the inclination angle (AG) of the fault is formed at 60°.

[0160] Fig. 18 is a diagram measuring the surface temperature of each part of the magnetic component, and the Rotate Angle item shows examples of forming the inclination angle (AG) of the single layer as 0°, 10°, 20°, 30°, 40°, 50°, and 60°, respectively. The OutL_Coil item measures the outermost temperature of the coil part, the OutL_Core item measures the outermost temperature of the core part, the Trans Core_back item measures the back temperature of the core part, the Trans Core_front item measures the front temperature of the core part, the Trans Inner_back item measures the back temperature of the inner coil part, the Trans Inner_front item measures the front temperature of the inner coil part, the Trans Origin item measures the center temperature of the core part, the Trans Outer_back item measures the back temperature of the outer coil part, and the Trans Outer_front item measures the front temperature of the outer coil part.

[0161] Referring to Figure 18, when the inclination angle (AG) of the fault was formed as 0°, the point where the lowest temperature was measured was 70.4°, and the point where the highest temperature was measured was 77.2°.

[0162] Additionally, when the inclination angle (AG) of the fault was formed at 40°, the point where the lowest temperature was measured was 64.1°, and the point where the highest temperature was measured was 70.3°.

[0163] When the inclination angle (AG) of the fault was formed at 60°, the point where the lowest temperature was measured was 64.5°, and the point where the highest temperature was measured was 73.0°.

[0164] In the experimental results above, it was shown that the cooling performance was the best when the inclination angle (AG) of the fault was formed at 40°.

[0165] As described above, the magnetic component according to one embodiment of the present invention can obtain the effect of reducing heat generation of the core itself by alleviating magnetic flux saturation of the core.

[0166] In addition, the present invention can obtain the effect of improving heat dissipation performance by directing the main flow of cooling gas along the single layer of the auxiliary core part formed on the core surface to a component or a heat-generating part requiring concentrated cooling.

[0167] In addition, the present invention can obtain the effect of increasing the heat exchange time and thereby improving the cooling efficiency by preventing the flow of cooling gas by a single layer of the auxiliary core part.

[0168] Although the present invention has been described as above, those skilled in the art will recognize that the present invention can be implemented in other forms while maintaining the technical spirit and essential features of the present invention.

[0169] The scope of the present invention will be fundamentally determined by the patent claims, but it should be interpreted that not only the configuration directly derived from the description of the patent claims, but also all changes or modified forms derived from equivalent configurations are included in the scope of the present invention.

Claims

1. Lower core; an upper core disposed on the lower core; and including a coil portion disposed between the upper core and the lower core; A magnetic component, wherein at least one of the upper core or the lower core includes a first region having a first thickness and a second region having a second thickness different from the first thickness.

2. In paragraph 1, Either the first region or the second region is deposited at a certain height on the core surface or is formed by increasing the thickness as an integral part to form an auxiliary core portion. The above auxiliary core part is a magnetic component that forms a single layer that interferes with the main flow of cooling gas.

3. In paragraph 2, A magnetic component in which the auxiliary core portion is formed in a separate form.

4. In paragraph 2, The above auxiliary core portion forms a fault layer that interferes with the main flow of cooling gas, The above fault is a magnetic component having an oblique inclination angle passing through the center of the core.

5. In paragraph 4, The above diagonal direction is the direction in which the busbar is connected.

6. In paragraph 2, The above auxiliary core part is a magnetic component that forms an orifice groove in the main flow direction of the cooling gas.

7. In paragraph 6, The above orifice home is a magnetic component having a wide inlet for cooling gas and a shape that gradually narrows toward the outlet.

8. In paragraph 2, The above auxiliary core portion is formed in the latter part of the core portion in the main flow direction of the cooling gas, An airfoil is formed in the front part of the core section to induce the descent of cooling gas. The above airfoil is a magnetic component formed at the front edge where the core section begins.

9. In paragraph 2, The above auxiliary core portion is formed in the latter part of the core portion in the main flow direction of the cooling gas, An airfoil is formed in the latter half of the core section to induce the descent of cooling gas. The above airfoil is a magnetic component formed at the corner of the single layer where the auxiliary core section begins.

10. In paragraph 1, A magnetic component formed so that the second thickness (T2) is thicker than the first thickness (T1).

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