JP2007227914A - Gapped core structure for magnetic component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a magnetic component having improved efficiency and improved creation possibility for the application of a circuit substrate without enlargement and occupying an unreasonable space. <P>SOLUTION: There is provided a magnetic component comprising: a monolithic core structure formed in a substantially rectangular body from a magnetic material which is a monolithic core structure in which the body is defined by end faces opposing to each other, side ends extending between respective end faces and opposing to each other, and an upper surface and a bottom surface connecting each end face with each side end; a first conductor opening portion constituted by being distanced from each end face, the upper surface, and the bottom surface which is a first conductor opening portion extending such that it passes through the body; a first gap formed in the body in an integrated manner and extending orthogonally relative to the first conductor opening which is a first gap extending through the body halfway; and a first conductor element for establishing a conductive path via the first conductor opening which is a first conductor element constituted as a dead end for surface mounting. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  This application is a continuation of part of the contents of US patent application Ser. No. 10 / 736,059. No. 60 / 435,414 filed Dec. 19, 2002, which is hereby incorporated by reference in its entirety. .

  The present invention relates generally to the creation of electronic components, and more particularly to the creation of magnetic components such as inductors.

  The types of magnetic parts are not limited to inductors and transformers, but also include at least one winding disposed around the core. In some parts, a core assembly is created by combining a plurality of ferrite cores with gaps. In use, the gap between the cores is required to store energy in the core. The gap between the cores is not limited to the inductance and DC bias characteristics at the time of open circuit, but affects various magnetic characteristics. Creating a uniform gap between cores, especially in small parts, is important for consistently producing reliable high quality magnetic parts.

  In some examples, an epoxy is used to bond the ferrite core to produce a bonded core assembly for the magnetic component. In an effort to make the core gap uniform, non-magnetic beads, usually spherical glass spheres, are mixed with the adhesive insulating material and applied between the cores to form a gap. During heat curing, the epoxy bonds the core and the beads provide voids in the core to form a gap. However, this bonding method basically depends on the stickiness of the epoxy and the ratio of the epoxy and beads for adhesive mixing applied between the cores. In some applications, it is pointed out that the bonded core is insufficiently bonded for the intended use, and it is very difficult to control the ratio of epoxy to glass sphere in the adhesive mix. Has been revealed.

  In other types of magnetic components, a non-magnetic spacer material is mounted between two half cores and the two are secured together with the spacer material properly held in the half cores. . This spacer material is frequently made from paper or Mylar® insulating material. In general, the two halves of the core and the spacer material are secured together by tape that is affixed to the outside of the core or by an adhesive that secures the two halves of the core together. Alternatively, two half cores are fixed by a clamp to maintain a gap between the half cores. In rare cases, the use of multiple pieces (two or more) of spacer material can complicate the task of stabilizing the united structure, which can be difficult and expensive.

  In addition, other types of magnetic components provide a ground gap in a portion of half the core. Then, with any of the above-described joining techniques, the portion excluding the gap of the half cores is fixed to the other half cores.

  Another method of creating a gap in the core structure starts with a monolithic core, and slices of core material are cut from the core (typically a toroid-shaped core). The gap is often filled with an adhesive or epoxy to restore the strength and shape of the core.

  Recently, composite magnetic ceramic toroids containing layered magnetic structures separated by nonmagnetic layers have been developed to form gaps. See, for example, US Pat. No. 6,162,311. In this way, the bonding material (eg, adhesive) and the outer gap material (eg, spacer) in the core structure can be saved.

  In any of the above means, in order to couple energy into the core in the form of a magnetic flux, a conductor is generally disposed through the core. The magnetic flux lines pass through and around the gap to complete the magnetic path in the core. When the conductor intersects the flux lines, a circulating current is induced in the conductor. Resistance in the conductor generates heat in response to current circulation. This reduces the efficiency of the magnetic component. Separating the conductor from the magnetic flux lines can reduce the amount of energy associated with the conductor and thus increase the efficiency of the magnetic component. However, this generally requires increasing the size of the magnetic component, which is not preferable from the viewpoint of production.

  Also, conventional magnetic components are generally assembled with a single core structure. When it is desired to use multiple inductors, for example, they must be physically separated to prevent mutual interference during operation. Separation of components occupies valuable space on the printed circuit board.

  Accordingly, a magnetic component is provided that has improved efficiency and improved fabrication possibilities for circuit board applications without increasing the size of the component and without occupying unreasonable space on the printed circuit board. It is hoped that.

  FIG. 1 is a perspective view showing an example of a typical gapd core structure 10 for a magnetic component. Magnetic components include inductors, transformers, and other magnetic components including gapd core structures. The core structure 10 includes a plurality of magnetic layers 12 having a laminated structure together with the nonmagnetic layer 14. The nonmagnetic layer 14 is a gap integrated in the core so as to separate the two magnetic layers 12 and extend between the two separated layers in order to block the magnetic path through the core structure 10. Form.

  As shown in FIG. 1, the core structure 10 is suitable for forming a single magnetic component, such as an inductor. The core structure 10 is constructed by bonding an unprocessed (non-fired) magnetic ceramic material layer that forms the magnetic layer 12 and an unprocessed nonmagnetic ceramic material layer that forms the nonmagnetic layer 14. To do. The non-magnetic ceramic material functions as a gap, while the magnetic ceramic material functions as a core.

  The portion of the ceramic material that makes up the stack of core structures 10 is removed to form areas for conductor elements (not shown in FIG. 1) or openings 16. In the illustrated embodiment, the opening 16 is substantially rectangular and is defined by a side edge 15 around the magnetic layer 12 and an edge 18 around the nonmagnetic layer 14. In order to form an inner hole that penetrates the core structure 10, the side surfaces 17 extend from the side edges 15 of the magnetic layer 12, and the top surface 19 extends from the edge 18 of the nonmagnetic layer 14. In other embodiments, the openings 16 and / or inner holes can be made in other shapes instead of the rectangle shown in FIG.

  When the magnetic layer 12 and the non-magnetic layer 14 are stacked to a suitable thickness by a known lamination process and all layers are joined together, the opening 16 is made into a conventional technique such as a known drilling process. Thus formed. The core structure 10 is then fired to develop the final shape and characteristics of the core structure. The gapd core structure 10 is made as a monolithic structure. Since the gap size can be steadily controlled in a large production lot size, a reliably controlled inductance value can be realized.

  The monolithic structure of the core structure 10 provides a number of manufacturing advantages. For example, this monolithic structure removes the adhesive bonding operation and the outer gap material with the attendant costs and difficulties, and as a result is less susceptible to separation. The integrated gap structure also allows very tightly controlled inductance values, and multiple small gaps (instead of one or two larger gaps in conventional core structures) can be used in the core during use. Can be used to reduce the magnetic flux loss and heat loss of the conductive material. Furthermore, the introduction of the gap does not require machining. Therefore, the result is that the magnetic component including the core structure 10 is robust, and it is possible to maintain a solid gap width control.

  A wide range of ferrite materials can be used as the magnetic medium to form the magnetic layer 12 in the core structure 10. Typical ferrite materials include manganese zinc ferrite, and special power ferrites, nickel zinc ferrite, lithium zinc ferrite, magnesium manganese manganese ferrite, and others that are used on a commercial basis and are more widely used than expected. It is. A wide range of ceramic materials that can be used as the nonmagnetic layer 14 include alumina and glass, cordierite, cordierite and glass, mullite, mullite and glass, zirconia, zirconia and glass, titanium Barium acid, and other titanates can be included. Further, the nonmagnetic ceramic material can include steatite, a mixture of ferrite and nonmagnetic ceramic, and weak magnetic ceramic that can be fired simultaneously with the ferrite material, or nonmagnetic ceramic having similar characteristics. Adding a glass phase to the nonmagnetic ceramic can improve the sintering temperature and firing shrinkage during production. This is important for: This is because non-magnetic ceramics must exactly match the thermal characteristics of the magnetic phase, that is, the ferrite phase. If the firing shrinkage of the two materials do not match well enough, the part produced will not function well.

  The embodiment shown in FIG. 1 includes three magnetic layers 12 and one nonmagnetic layer 14. On the other hand, however, it is contemplated that more or less magnetic layer 12 may be utilized with more or less non-magnetic layer 14 in alternative embodiments without departing from the scope of the present invention. Furthermore, the core structure 10 is represented by a substantially rectangular structure in FIG. However, on the other hand, the core structure 10 with other shapes is not limited to the toroid shape known in the industry, but it is worthwhile to be able to adopt it as an alternative embodiment.

  The type of ferrite used for the magnetic layer 12 and the thickness of the nonmagnetic layer 14 affect the magnetic properties of the core structure 10 and ultimately affect the performance of the magnetic components obtained during use. The power loss density can be changed, for example, by changing the initial ferrite composition. For example, in switching voltage regulator components, the initial ferrite composition is particularly effective in reducing power loss. Another important characteristic, the effective magnetic permeability, is mostly controlled by the thickness of the nonmagnetic layer 14.

  FIG. 2 is a side view of the core structure to which the conductor element 20 is attached. In an exemplary embodiment, such as in FIG. 2, conductor element 20 is made from a known conductive material and is formed or bent at each end after passing through conductor opening 16 (see FIG. 1). . In the embodiment shown in FIG. 2, the core structure 10 and the conductor element 20 are well suited to form an inductor. The assembly of the core structure 10 and the conductor element 20 can be easily automated as required. The plurality of conductor elements 20 can be inserted into the core structure 10 as a single lead frame and can be formed and trimmed for final product. As a result, a high-capacity magnetic component can be efficiently produced at a relatively low cost, for example, as compared with known inductors.

  FIG. 3 is a schematic cross-sectional view of the core structure 10 and the conductor element 20. This figure shows that the conductor element 20 is held in contact with the non-magnetic layer 14 while being substantially centered with respect to the conductor opening 16. That is, the conductor element 20 is in contact with the upper surface 19 of the nonmagnetic layer 14, but has a space of approximately equal distance from each side edge 15 of the magnetic layer 12 in the opening 16. Thus, the nonmagnetic gap extends directly under the conductor element 20, and the conductor element 20 has a gap between the inner surface 17 of the opening 16.

  As shown in one exemplary embodiment in FIG. 3, the conductor element 20 complements the conductor opening 16 in shape, so in the above embodiment, each complement is substantially rectangular in cross section. However, it is worthwhile that other cross-sectional shapes with conductor elements 20 and conductor openings 16 can be employed in alternative embodiments of the present invention and can realize at least some of the advantages of the present invention. In further embodiments, it is noted that the conductor element 20 and the conductor opening 16 need not have complementary shapes in order to realize the immediate benefits of the present invention.

  Further, although the conductor element 20 shown in FIG. 2 is shown for insertion into the core structure 10, as an alternative, conductive material can be placed on the surface of the core structure 10, or thin film processing. It is anticipated that known conductive inks such as those used in can be utilized to print on the core structure 10.

  FIG. 4 schematically shows the magnetic flux lines of the core structure 10 in use, but it is particularly noted that the conductor element 20 does not intersect the magnetic flux lines. Thus, the current induced in the conductor element 20 is saved, the heat loss associated with the induced current is avoided, and the efficiency of the magnetic component is improved. Therefore, improved magnetic component efficiency can be obtained with a small component size.

  As known to those skilled in the art, component efficiency is of greatest concern at high switching frequencies. Accordingly, the structure described above is suitable for single-turn conductor elements 20 and particularly for high frequency applications. However, it is worthwhile to apply a conductor element having multiple turns as well in an alternative embodiment of the present invention.

  FIG. 5 shows a second embodiment of the core structure with gaps 30 and shows a plurality of core structures with gaps. Stacks 12 and 14 of magnetic and non-magnetic materials described above for a single structure produce a plurality of magnetic components in the same manner as described above, based on a single or single core structure 30. be able to. Thus, two, three, or more magnetic components, such as inductors, can be constructed as a single core structure 30 as shown, for example, in FIG. At this time, a conductor element such as the conductor element 20 (see FIGS. 2 and 3) is placed in the opening 16 or the conductor element is formed on the surface of the core structure 30 by another method.

  Utilizing a single core structure 30 integrated for multiple magnetic components results in the cost of single component packaging and handling being lower than the cost of handling multiple components. Lower costs are obtained. In addition, mounting with fewer components can also result in cost savings, thus reducing the overall system cost. Yet another advantage is that the core structure 30 takes advantage of the saved area on the circuit board as compared to combining individual magnetic components (single inductors shown in FIGS. 2 and 3). The integration of a plurality of inductors in a single core structure 30 is smaller than the space occupied by the same number of individual components and cores. The main reason is that the physical gaps required by the individual parts are not necessary for the integrated core structure 30.

  As shown in FIG. 5, the core structure 30 is formed by stacking a series of magnetic layers 12, and the magnetic layer 12 is divided by at least one nonmagnetic layer 14. The magnetic layers 12 extending in the horizontal direction are stacked in the vertical direction, and the number of steps of the conductor openings 16 is formed by the stacked magnetic layers 12 and nonmagnetic layers 14. The conductor openings 16 are separated by a nonmagnetic layer or insulating layer 32 extending in the vertical direction, and the insulating layer 32 extending in the vertical direction is stacked in the vertical direction in which each conductor opening 16 exists. And the nonmagnetic layer 14 are coupled. Therefore, the core structure 30 can be seen as forming a larger core structure 30 by configuring a plurality of core structures 10 (see FIGS. 1 to 4) in parallel and connecting them together. An insulating layer 32 extending in the vertical direction can be bonded between the laminates 12 and 14 before and after the opening 16 is formed, and the core structure 30 is fired to a final form as a monolithic structure.

  Once the monolithic structure is completed, a conductor element such as the conductor element 20 already described is attached to each of the conductor openings 16 in order to form a plurality of magnetic components that operate within the same monolithic structure. This mounting operation results in a lower overall cost solution, especially when using an automatic component mounting device than when using separate components such as inductors. The inductor configuration coupled by the core 30 can use less space on the circuit board than each of the plurality of inductors. This is because the physical interference area or “keep-out” area is no longer needed. In addition, the use of a single core structure 30 for multiple conductor elements allows each inductance value to be tracked together. This is because heating to each inductor has a similar effect on other inductors on the same structure.

  The core structure 30 is particularly suitable for a multi-voltage regulator module (VRM), which is often used for high performance and higher current applications. The total current supplied from the VRM to the load is the sum of the current supplied by each VRM part. Because multiple inductors can be used in the voltage regulation circuit, it is advantageous to assemble one or more inductors into a single package by utilizing the core structure 30.

  The stacks 12, 14 of the core structure 30 include four magnetic layers 12 and one nonmagnetic layer 14, but one or more nonmagnetic layers 14 are less than described above without departing from the scope of the present invention. Obviously, a large number of magnetic layers 12 can be applied. Furthermore, as mentioned above in relation to the core 10, in order to obtain the immediate effect of the present invention, the core structure 30 does not have to be rectangular as a whole, and the shape of the conductor opening is rectangular. There is no need. Accordingly, in different embodiments, various types of shapes can be employed as the overall shape of the core structure 30 and / or the shape of the conductor openings 16.

  FIG. 6 is a third embodiment for a typical core structure 50. In this example, multiple core structures are stacked one after the other and separated by a non-magnetic insulating layer 52. In the illustrated embodiment, each core structure includes two nonmagnetic layers 14 sandwiched between magnetic layers 12, and an insulating layer 52 extending substantially parallel to the layers 12, 14 in each core structure. Including. The nonmagnetic layer 14 defines opposite side surfaces of the conductor opening 16. The insulating layer 52 can be bonded to any of the stacks 12 and 14 before and after the opening 16 is formed. Thus, the core structure 50 is fired into a final form as a monolithic structure.

  The stacks 12, 14 of the core structure 50 include three magnetic layers 12 and two nonmagnetic layers 14, but without departing from the scope of the present invention, more or fewer nonmagnetic layers 14 may be used. Obviously, the present invention can be applied to a smaller or larger number of magnetic layers 12. Furthermore, as mentioned above in relation to the core structure 30, in order to obtain the immediate effect of the present invention, the core structure 50 does not have to be rectangular as a whole, and the shape of the conductor opening is rectangular. There is no need to be. Accordingly, in different embodiments, various types of shapes can be employed as the overall shape of the core structure 50 and / or the shape of the conductor openings 16.

  Although the embodiment of FIG. 6 is shown in a configuration that includes three magnetic components in a single core structure, in further and / or alternative embodiments, more or fewer than three magnetic components or circuits. It is expected that can be combined into a single core structure.

  Apart from the structural differences, the core structure 50 provides substantially the same advantages as the core structure 30 (see FIG. 5).

  Gapped core structures are utilized to create magnetic components such as inductors, transformers, or other magnetic components. In order to reduce the magnetic loss of the fringing of the conductor material, avoid the coupling material and the outer gap material used in the conventional core structure and replace multiple small gaps (instead of one larger one or two gaps) ) To improve electrical efficiency. Also, the gapd structure makes it possible to control the inductance value very reliably. In order to obtain maximum efficiency results, the gap is set so that the outer edge magnetic flux can exist away from the conductor. Also, the multiple inductors can be assembled with a single core structure so that overall cost and overall size can be saved.

  7-9 illustrate another embodiment of a gapped core structure 100. FIG. This core structure with a gap is for magnetic parts applied to inductors, transformers, and other magnetic parts including the core structure with gaps, and realizes similar advantages to the core structures 30 and 50 described above. Similar to the core structures 30, 50, the gapped core structure 100 is commonly used in outer gap materials, adhesive materials used simultaneously, and conventional gapped core structures as surface mount components applied to circuit boards. Eliminate any adhesives. Therefore, the reliability problem related to the separation of a plurality of components of the core to be bonded together, which has been affected by the core structure by conventional bonding, is avoided. In addition, the creation of the core structure 100 is simpler than the conventional core structure, and space saving can be realized when the core structure 100 with a gap is mounted on a circuit board.

  FIG. 7 is a side view of the core structure 100 with a gap. FIG. 8 is a bottom view of the core structure 100 with a gap, and FIG. 9 is a cross-sectional view of the structure. With reference to FIGS. 7-9, the core structure 100 can include a substantially rectangular body 102. The rectangular body includes opposing end faces 104 and 106, opposing side edges 107 and 108 extending between the end faces 104 and 106, and the end faces 104 and 106 and the side ends 107 and 108, respectively. A top surface 110 and a bottom surface 112 that extend between and connect to each other. The fuselage 102 can be elongated and can be defined by a vertical axis 114 and a horizontal axis 116. As shown, the side edges 107 and 108 and the top and bottom surfaces 110 and 112 extend parallel to the longitudinal axis 114 and the end faces 104 and 106 extend generally parallel to the horizontal axis 116. Although the figure shows a typical rectangular fuselage 102, it will be appreciated that in other embodiments, another alternative shape fuselage 102 may be used if desired.

  The body 102 can be made by integral molding and can be made from a known magnetic medium or magnetic material. The magnetic material or the like can include any of the ferrite materials already described in one exemplary embodiment. Known processes or known techniques can be used to create the fuselage 102. Unlike the core structures 30 and 50 described above, particularly when constructing the core structure 100, the core structure 100 does not include non-magnetic materials such as the non-magnetic layers 14, 32 described above. That is, instead of being monolithically formed from dissimilar materials in the manner described above with respect to the core structures 30, 50, the core structure body 102 is made from a uniform magnetic material. Specifically, the fuselage is made in a single monolithic part with relatively constant magnetic properties throughout the fuselage 102 without the use of intervening parts, ie, non-magnetic or insulating material sections. In addition, in one exemplary embodiment, the fuselage 102 is made entirely of magnetic material, as opposed to a composite material such as a core material having individually dispersed air gaps. The composite material corresponds to, for example, a powdery iron component and a resin binder mixed together at the particle level. As a result, the created fuselage produces a gap effect even if there is no individually dispersed gap formation on the structural surface. However, in other embodiments, composite materials can be used if desired.

  Conductor openings 118, 120 (see FIG. 7) can be formed in the fuselage 102. The openings 118 and 120 can extend between the side ends 107 and 108, that is, through the body 102, as can be seen in FIG. Each of the openings 118 and 120 is present at each of the side ends 107 and 108 with a space between the side ends 107 and 108 and the top surface 110 and the bottom surface 112. Each of the conductor openings 118, 120 extends generally in the normal direction, ie perpendicular to the ends 107 and 108, and is spaced from the outer periphery of the ends 107 and 108. This outer periphery is defined by the top surface 110 and bottom surface 112 and the side edges 107 and 108 in the illustrated embodiment. That is, each of the conductor openings 118 and 120 is placed at an inner position with respect to the outer periphery of the side ends 107 and 108.

  The conductor openings 118, 120 can be other shaped openings in other embodiments, but can also be rectangular openings elongate in a direction parallel to the longitudinal axis 114, for example. The conductor openings 118 and 120 are not limited to molding methods and / or manufacturing techniques familiar to those skilled in the art, and can be formed by being integrated in the body 102 by a known method. Although two openings 118, 120 are shown in FIGS. 7-9, it will be appreciated that a greater or lesser number of openings 118, 120 may be implemented as an alternative.

  Further, the separated nonmagnetic gaps 122 and 124 can be integrated in the body 102. Each gap 122, 124 can be associated with one of the conductor openings 118, 120. The gaps 122 and 124 are physically formed by, for example, a known molding method and / or production technique. In particular, no outer gap material, simultaneously used adhesive material, and adhesive are used to form the gaps 122, 124 in any way. Also, the gaps 122, 124 do not require any filler material other than air. That is, the gaps 122, 124 are sometimes formed without the use of an insulating material, sometimes referred to as the outer gap material, which is applied to the fuselage in the exemplary embodiment. However, it will be appreciated that in alternative embodiments, the gaps 122, 124 can optionally be filled with non-magnetic material, although some of the advantages of the present invention can be realized.

  In one exemplary embodiment, as best shown in FIG. 7, the gaps 122, 124 can extend perpendicular to each of the conductor openings 118, 120. For example, each of the gaps 122, 124 can have opposing ends 126 and 128. One end 126 terminates at each of the conductor openings 118, 120 and provides an opening for each of the conductor openings 118, 120. Accordingly, the ends 126 of the gaps 122, 124 are placed in fluid communication with each of the conductor openings 118, 120. Opposing ends 128 of each gap 122, 124 extend to the periphery of the side ends 107, 108, and more particularly to the bottom surface 112. Each gap 122, 124 generally bisects the conductor openings 118, 120 and extends in the normal direction, ie orthogonal to the conductor openings 118, 120. As a result, when viewed from the side, the gaps 122 and 124 form a T-shaped arrangement with the gap itself and the conductor opening.

  As shown in FIG. 8, each gap 122, 124 extends across both ends from one side end 107 to another side end 108 in a direction parallel to the horizontal axis 116. That is, the gaps 122 and 124 penetrate between the side ends 107 and 108 in the horizontal direction while traversing the body 102. However, each gap 122, 124 can extend vertically, extends between the top surface 110 and the bottom surface 112, and extends only on one side of the conductor openings 118, 120. More specifically, each gap 122, 124 can extend between the conductor openings 118, 120 and the bottom surface 112 in the embodiment shown in FIG. In particular, each gap 122, 124 does not extend between the conductor openings 118, 120 and the upper surface 110 of the fuselage 102. Accordingly, the gaps 122 and 124 extend partway between the upper surface 110 and the bottom surface 112 of the body 102. Extending each gap 122, 124 halfway is particularly in contrast to the half core bonded together with the gap material extending across the half core from end to end. It is. The monolithic fuselage 102 integrates the gaps 122 and 124 within the single core structure 100, thereby eliminating the difficulty of assembly and reliability of core separation during use, and a plurality of core components. Can be reduced. With this single core structure 100, material costs and assembly costs are reduced compared to conventional core structures.

  The bottom surface 112 of the fuselage 102 can form a surface 130 having nicks or depressions. This surface 130 defines a land portion (described below) of the conductor that is incorporated into the core structure 100.

  FIGS. 10-12 are external views similar to FIGS. 7-9, but these figures show a conductor element 140 inserted into the core structure 100. More specifically, this conductor element 140 is inserted into the openings 118, 120 of the fuselage 102 to form a magnetic component 136 (see FIG. 10). The conductor element 140 complements the conductor openings 118, 120 in shape. Also, the conductor element 140 can be, for example, generally rectangular, and can be a planar ribbon-shaped conductor, such as made from a known conductive material such as copper or copper alloy as an example. . The conductor element 140 generally extends linearly through each of the conductor openings 118, 120 and extends the entire section between the side edges 107, 108 of the fuselage 102, as can be seen in FIG. The opposite end portions 142 of the conductor element 140 enclose the side ends 107 and 108 of the fuselage 102, and contact the periphery of the recess 130 formed in the bottom surface 112 of the fuselage 102. Thus, the end 142 of the conductor element 140 defines a rectangular surface mounting termination pad 144 on the bottom surface 112 of the fuselage 102 (see FIG. 11). When connecting to the wiring on the circuit board (not shown), the surface mounting termination pad 144 enables reliable electrical connection between the magnetic component and the wiring on the board.

  Conductive element 140 can be made simultaneously with a lead frame (not shown) from a planar sheet of conductive material by known stamping, stamping or forming techniques. The lead frame can also be used to simultaneously insert the conductor element 140 into the body 102 of the core 100. The lead frame can then be cut from the conductor element 140 at an aligned position, and the end 142 of the conductor element 140 can be bent or formed into a C-shaped arrangement as shown in FIG. Thus, the assembly of conductor element 140 can be completed in a fraction of the time by using automated processing and machinery.

  When conductor elements 140 are incorporated into the core 100, each conductor element 140 and associated gaps 122, 124 can function as separate inductors operating on a single core structure 100. In addition, each conductor element 140 can operate in connection with a different phase current, and as a result, can be supplied as a two-phase magnetic component contained within a single core structure 100. The integrally formed core structure 100 provides space savings on the circuit board as compared to a separate inductor component having a separate core structure.

  Thus, a surface mount magnetic component having an integrally formed gapd core structure 100 provides the same advantages as obtained with the core structures 30 and 50 already described. Since the core structure 100 can solve the problem of separation of the core itself by virtue of the integrally formed core 100, the core structure 100 can be supplied with reduced production costs and can be produced with improved reliability.

  FIGS. 13-18 show a fifth embodiment associated with the gaped core structure 200 and the magnetic component 201. In this embodiment, features similar to the core structure 100 are denoted with similar reference characters.

  Gapped core structure 200 is similar to gapd core structure 100, but it is apparent that the number of conductor openings, accompanying gaps, and conductor elements has increased. That is, the body 202 of the core structure 100 includes four additional conductor openings 204, 206, 208 and 210 in addition to the conductor openings 118 and 120. Similarly, in addition to the gaps 122, 124, the fuselage 202 includes individual gaps 212, 214, 216 and 218. These individual gaps are formed in a manner and arrangement substantially similar to the gaps 122, 124 already described. When the conductor element 140 is inserted into the fuselage 202 through the conductor opening and formed in a C-shaped arrangement as shown in FIG. 18, the conductor element 140 and the respective gaps 212, 214, 216 and 218 are Functions as six different surface mount inductor components integrated within a single core structure 200. Each conductor element 140 provides conductive space on the circuit board via surface mount terminations so that it can operate in connection with six different phase currents while substantially saving space on the circuit board. Can be connected to the department. In this way, the core structure 200 realizes the same advantages as the core structure 100.

  The core structures 100 and 200 are considered to be particularly suitable for applications in multi-voltage regulation modules (VRMs) that are sophisticated and often used in more advanced current applications. However, in other applications, the core structures 100 and 200 are considered beneficial, so the present invention is not limited to any particular end use or end application.

  Here, one embodiment of a magnetic component describes a magnetic component that includes a monolithic core structure made from a magnetic material into a substantially rectangular body. The body is defined by opposing end surfaces, opposing side ends extending between the end surfaces, and top and bottom surfaces interconnecting the side ends and the end surfaces. The first conductor opening is located at a distance from each of the end surfaces and the top and bottom surfaces and extends through the body. The first gap is formed by being integrated in the body and extends perpendicular to the conductor opening. The gap extends only part way through the body and the first conductor element establishes a conductive path through the first conductor opening. The first conductor element constitutes a surface mounting end.

  As an option above, the conductor element can be a rectangular conductor. The second conductor opening is formed in the body and can be separated from the first conductor opening. The second gap is formed in the fuselage and can extend orthogonally to the second conductor opening. The second conductor element can establish a conductive path through the second conductor opening. The first gap extends toward the first conductor opening, and the first gap and the first conductor opening can constitute a T-shaped arrangement. The fuselage is defined by a vertical axis and a horizontal axis, in which the first conductor opening and the first gap extend generally parallel to the horizontal axis and the first conductor opening. And the first gap extends generally perpendicular to each other. The bottom surface includes opposing concave surfaces, and the first conductor element can wrap the opposing surfaces and the concave surfaces. The gap is formed without using a spacer made of a nonmagnetic material.

Here, an embodiment of a core assembly for a surface-mounting electronic component will be described. The core assembly is
A core including a monolithic fuselage made of a uniform magnetic material;
A plurality of conductor openings formed in the core, each of the plurality of conductor openings being spaced apart from each other;
A plurality of gaps that are integrated into the core structure without the use of insulating spacer material.
Each of the plurality of gaps is associated with each of the plurality of conductor openings and extends partway through the body.

Here, an embodiment of the electronic component for surface mounting will be described.
The electronic component includes a single core composed of a body made uniformly from a magnetic material, and the body includes a single core having a vertical axis and a horizontal axis.
The plurality of conductor openings are a plurality of conductor openings formed in the core, extending parallel to the horizontal axis, and spaced from each other along the vertical axis.
A plurality of nonmagnetic gaps are physically formed in the core structure adjacent to each conductor opening, and the plurality of nonmagnetic gaps use an insulating material applied to the fuselage. Formed without. A conductor element is placed in each of the conductor openings and the gap is placed adjacent to the conductor element, resulting in the formation of multi-phase electronic components within a single core.

  As an option, the core structure can include two conductor openings. As an alternative, the core structure may include six conductor openings. The gap can only extend between one of the conductor openings and one of the side edges. The component can be an inductor.

  Here, an embodiment of the magnetic component will be described. The magnetic component includes an integrally formed core structure that is uniformly formed on a body having a non-toroid shape from a magnetic material, and the body includes an integrally formed core structure having side surfaces facing each other. The first conductor opening extends between the opposite side surfaces from end to end on both sides, and is located at a distance from the periphery of each of the opposite side surfaces inside the body. The gap is formed by being integrated into the body without using an outer gap material applied to the body. The gap has a first end and a second end, the first end terminating at a first conductor opening, opening the first conductor opening, and the second end. The end portion of the portion extends to the peripheral portion. As an option, the magnetic component can further include a second conductor opening and a second gap.

  The magnetic component will be described here. The magnetic component includes an integrally formed core structure that is monolithically made from a uniform magnetic material to a fuselage having opposing sides. The first conductor opening extends between the opposing side surfaces from end to end on both side surfaces, and is positioned at an interval from the periphery of each side surface to the inside. The first gap is formed by being integrated in the body without using an outer gap material applied to the body. The gap has a first end and a second end, the first end terminating at a first conductor opening, opening the first conductor opening, and the second end. The end portion of the portion extends to the peripheral portion. The C-shaped conductor element extends linearly through the conductor opening. The conductor element has opposite ends, and each opposite end wraps around a peripheral portion of the side surface to define a surface mounting end of the magnetic component. Optionally, the magnetic component further includes a second conductor opening and a second gap, and the magnetic component is an inductor.

  While the invention has been described in connection with various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. I will.

It is a perspective view which shows an example of the typical core structure with a gap for magnetic component preparation. It is a side view of the core structure shown in FIG. 1 which attached the conductor. FIG. 3 is a schematic cross-sectional view of the core structure and conductor shown in FIG. 2. FIG. 4 is a schematic cross-sectional view of the portion in FIG. It is a figure used as the 2nd typical Example of a core structure with a gap. FIG. 6 is a diagram illustrating a third example of a typical core structure. It is a side view of the 4th example of a core structure with a gap. It is a bottom view of the core shown in FIG. It is sectional drawing of the core shown in FIG. FIG. 8 is a side view of the core structure shown in FIG. 7 with a conductor attached. It is a bottom view of the core structure shown in FIG. It is a side view of the core structure shown in FIG. It is a side view of the 5th example of a core structure with a gap. It is a bottom view of the core shown in FIG. It is sectional drawing of the core shown in FIG. It is a side view of the core structure shown in FIG. 13 which attached the conductor. It is a bottom view of the core structure shown in FIG. It is a side view of the core structure shown in FIG.

Explanation of symbols

10 Core structure (with gap)
12 Magnetic layer 14 Nonmagnetic layer 15 Side end (end of magnetic layer 12)
16 Conductor opening 17 Side surface (Inside of conductor opening 16)
18 end (end of nonmagnetic layer 14)
19 Upper surface (the upper surface of the nonmagnetic layer 14)
20 Conductor element 30 Core structure (with gap)
32 Insulating layer (nonmagnetic layer)
50 Core structure (with gap)
52 Insulating layer 100 Core structure (with gap)
DESCRIPTION OF SYMBOLS 102 Body 104 End surface 106 End surface 107 Side end 108 Side end 110 Upper surface 112 Bottom surface 114 Vertical axis 116 Horizontal axis 118 Conductor opening 120 Conductor opening 122 Gap 124 Gap 126 End (End of gap 122, 124)
128 end (end of gap 122, 124)
130 Surface (recessed portion of bottom surface 112)
136 Magnetic component 140 Conductor element 142 End (end of conductor element 140)
144 Surface mount termination pad 200 Core structure (with gap)
DESCRIPTION OF SYMBOLS 201 Magnetic component 202 Body 204 Conductor opening 206 Conductor opening 208 Conductor opening 210 Conductor opening 212 Gap 214 Gap 216 Gap 218 Gap

Claims (32)

A magnetic component,
A monolithic core structure made from a magnetic material into a substantially rectangular body, the body comprising opposing end faces, opposing side edges extending between the end faces, and each end face and each A monolithic core structure defined by the top and bottom surfaces interconnecting the side edges;
A first conductor opening extending from and through each of the end surfaces and the top and bottom surfaces, the first conductor opening extending through the body;
A first gap formed integrally with the body and extending perpendicular to the first conductor opening, the first gap extending partway through the body;
A magnetic component comprising: a first conductor element that establishes a conductive path through the first conductor opening, the first conductor element being configured as a surface mount termination.   The magnetic component according to claim 1, wherein the conductor element is a rectangular conductor. A second conductor opening formed in the body and spaced from the first conductor opening;
A second gap formed in the body and extending at a right angle to the second conductor opening;
The magnetic component according to claim 1, further comprising: a second conductor element that establishes an electrical path through the second conductor opening.   The magnetic component according to claim 1, wherein the first gap extends to the first conductor opening.   The magnetic component according to claim 1, wherein the first gap and the first conductor opening constitute a T-shaped arrangement.   The fuselage is defined by a vertical axis and a horizontal axis, and the first conductor opening and the first gap extend substantially parallel to the horizontal axis, and the first conductor opening and the first The magnetic component according to claim 1, wherein the gaps extend substantially orthogonal to each other.   2. The magnetic component according to claim 1, wherein the bottom surface includes opposing concave surfaces, and the first conductor elements that wrap the end surfaces and the concave surfaces.   The magnetic component according to claim 1, wherein the conductor element complements the conductor opening with a shape.   The magnetic component according to claim 1, wherein the gap is formed without using a spacer made of a nonmagnetic material. A core assembly for electronic components for surface mounting,
A core including a monolithic fuselage made of a uniform magnetic material;
A plurality of conductor openings formed in the core, each of the plurality of conductor openings being spaced apart from each other;
A plurality of gaps integrated into the structure of the core without the use of insulating spacer material, each of the plurality of gaps being associated with a separate plurality of the conductor openings; and A core assembly including a plurality of gaps extending partway through the fuselage.   The core assembly of claim 10, further comprising a conductor element in each individual conductor opening.   The core assembly of claim 10, wherein each of the gaps extends substantially perpendicular to the individual conductor opening.   The core assembly of claim 10, wherein the conductor opening is substantially rectangular.   The core assembly of claim 10, wherein each of the gaps communicates with the individual conductor opening.   The core assembly of claim 10, wherein each of the conductor openings and the accompanying gap constitute a T-shaped arrangement.   The core assembly of claim 10, wherein the gap extends perpendicular to the conductor opening. Electronic components for surface mounting
A single core comprising a fuselage that is uniformly made from magnetic material, the fuselage comprising a single core having a longitudinal axis and a transverse axis;
A plurality of conductor openings formed in the core and extending parallel to the horizontal axis, the conductor openings spaced apart from each other along the vertical axis direction;
A plurality of nonmagnetic gaps physically formed in the core structure adjacent to each of the conductor openings, wherein the nonmagnetic gap is formed without using an insulating material applied in the fuselage. When,
A conductor element placed in each of the conductor openings, the conductor element forming a multi-phase electronic component in the single core by the gap placed adjacent to the conductor element; Electronic components for mounting.   The electronic component according to claim 17, wherein the structure of the core includes two conductor openings.   The electronic component according to claim 17, wherein the structure of the core includes six conductor openings.   The electronic component according to claim 17, wherein the gap extends at a right angle to the individual conductor openings.   The electronic component according to claim 17, wherein each of the gaps communicates with one of the conductor openings.   The electronic component according to claim 17, wherein the conductor opening is substantially rectangular.   The electronic component according to claim 17, wherein the gap forms a T-shaped arrangement integrally with the conductor opening.   The electronic component according to claim 17, wherein the body is substantially rectangular.   The electronic component according to claim 17, wherein the gap simply extends between one of the conductor openings and one of the side edges.   The electronic component according to claim 17, wherein the electronic component is an inductor. A magnetic component,
An integrally formed core structure uniformly formed on a body having a non-toroid shape from a magnetic material, the body having an integrally formed core structure having opposite side surfaces;
A first conductor opening extending through between the opposing side surfaces, the first conductor opening being located at an inner distance from the periphery of each of the opposing side surfaces When,
A gap formed integrally with the fuselage without using an outer gap material applied to the fuselage, the gap having a first end and a second end, the first end Is a magnetic component that includes a gap that terminates at the first conductor opening, opens the first conductor opening, and the second end extends to the periphery.   28. The magnetic component according to claim 27, further comprising a second conductor opening and a second cap.   28. The magnetic component according to claim 27, further comprising a rectangular conductor inserted into the first conductor opening and enclosing the periphery of the side surface. A magnetic component,
A single core structure monolithically made from a uniform magnetic material to a fuselage having opposing sides;
A first conductor opening extending through between the opposing side surfaces, the first conductor opening being located at an inner distance from the periphery of each of the opposing side surfaces When,
A first gap formed integrally with the fuselage without using an outer gap material applied to the fuselage, wherein the first gap comprises a first end and a second end. The first end terminates at the first conductor opening, opens the first conductor opening, and the second end extends to the periphery. When,
A C-shaped conductor element extending linearly through the conductor opening, and having opposing ends that wrap around the periphery of the side surface to define a surface mount termination for the magnetic component And a magnetic component including a letter-shaped conductor element.   31. The magnetic component according to claim 30, further comprising a second conductor opening and a second cap.   The magnetic component according to claim 30, wherein the magnetic component is an inductor.

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