TW202416306A - Magnetic device - Google Patents

Abstract

The present invention discloses a magnetic device. The magnetic device comprises a magnetic core and at least two windings. The magnetic core comprises a circular main body and a hollow portion. Each winding comprises a plurality of coils. Each coil is penetrated through the hollow portion and disposed around the circular main body. The plurality of coils of the at least two windings are disposed around the circular main body to form at least three surrounding intervals. All coils belong to each surrounding interval of the at least three surrounding intervals except last surrounding interval forms at least three surrounding layers stacked with each other. The number of the at least three surrounding layers of each surrounding interval of the at least three surrounding intervals except last surrounding interval is odd.

Description

Magnetic components

The present invention relates to a magnetic component, and more particularly to a magnetic component having at least three winding zones.

The application range of magnetic components is quite wide, such as communication systems, signal processing systems, filters and other electronic products, all of which require magnetic components to achieve the purpose of the circuit. Its structure is mainly composed of windings and magnetic cores. In application, the winding part is often wound on the magnetic core using the bank winding method. Generally speaking, the traditional bank winding method is to make the windings evenly wound on both sides of the magnetic core, and maintain a specific distance in the middle of the windings without overlapping windings, and set an isolation sheet in the middle of the windings to achieve the insulation effect between the windings. However, the impedance of magnetic components using the traditional stacking winding method is low, and the bandwidth coverage cannot meet the requirements of current electronic products.

Therefore, how to develop a magnetic component that overcomes the above-mentioned shortcomings is an urgent need at present.

The purpose of the present invention is to provide a magnetic component, which uses two winding groups to be wound on the annular body of the magnetic core to form at least three winding sections, wherein all the coils in each of the at least three winding sections except the last winding section constitute at least three winding layers stacked on each other, and the number of the at least three winding layers in each of the at least three winding sections except the last winding section is an odd number. The magnetic component of the present invention can have the advantages of increasing impedance value and increasing bandwidth through the design of the above-mentioned winding winding method. In addition, at least two windings of the magnetic component of the present invention are composed of completely insulated wires, so that at least two windings can be arranged intertwined with each other or stacked on the annular body. Therefore, the magnetic component of the present invention does not need to be additionally provided with an isolation sheet, thereby achieving the effect of reducing costs.

To achieve the above-mentioned object, a more general implementation of the present invention is to provide a magnetic component, including a magnetic core and at least two windings. The magnetic core has an annular body and a hollow area. Each winding has a plurality of turns, each of which passes through the hollow area and is wound on the annular body, and the plurality of turns of the at least two windings are wound on the annular body to form at least three winding sections, and all the turns in each of the at least three winding sections except the last winding section constitute at least three winding layers stacked on each other, and the number of at least three winding layers in each of the at least three winding sections except the last winding section is an odd number.

Some typical embodiments that embody the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can have various variations in different aspects without departing from the scope of the present invention, and the descriptions and drawings are essentially used for illustration rather than for limiting the present invention.

Please refer to Figure 1, Figure 2 and Figure 3, wherein Figure 1 is a schematic diagram of the structure of the magnetic component of the first embodiment of the present invention, Figure 2 is a schematic diagram of the exploded structure of the magnetic component shown in Figure 1, and Figure 3 is an equivalent circuit structure diagram of the power module to which the magnetic component shown in Figure 1 is applied. In terms of circuit structure, the magnetic component of the present invention can constitute a common mode filter inductor L (Common Mode Choke) and be applied to a power module, such as a filter circuit. As shown in Figure 3, the power module 1 receives the electric energy provided by the alternating current power source AC, and filters it through the common mode filter inductor L, so as to output the filtered electric energy through the output end.

In the actual structure, as shown in FIG. 1 and FIG. 2, the magnetic assembly 2 includes a magnetic core 3 and at least two windings. The magnetic core 3 of this embodiment is a cylinder with a hollow structure, and has an annular body 31 and a hollow area 32. The annular body 31 has an upper surface 311, a lower surface 312, an outer annular side 313 and an inner annular side 314. The upper surface 311 and the lower surface 312 are arranged opposite to each other. The outer annular side 313 and the inner annular side 314 are respectively located between the upper surface 311 and the lower surface 312, and the outer annular side 313 surrounds the outer side of the inner annular side 314, and the inner annular side 314 is arranged to surround and is located in the hollow area 32. Of course, in some embodiments, the structure of the magnetic core is not limited to being composed of a hollow cylinder, but can be composed of a hollow ring column, that is, it can be composed of a donut shape.

In this embodiment, at least two winding groups of the magnetic component 2 are composed of completely insulated wires and are intertwined with each other. Therefore, in FIG. 1 and FIG. 2 , the winding group 4 is used to represent at least two winding groups intertwined with each other. The withstand voltage of each winding group 4 is greater than 1.5 kV, that is, when the frequency is 60 Hz and the voltage between the windings is 1800 V, the leakage current is less than or equal to 1 mA, and each winding group 4 has a plurality of turns, each turn is wound on the annular body 31 and passes through the hollow area 32, and the winding direction of each turn can be from the outer ring side 313 of the annular body 31 along the upper surface 311 (or the lower surface 312) toward the inner ring side 314. The plurality of turns of each winding set 4 can be divided into three groups and wound on the annular body 31 to form at least three winding sections. As shown in FIG. 2 , the at least three winding sections include a first winding section 51, a second winding section 52, and a third winding section 53, and all the turns in each winding section form a stacked structure. The number of winding layers between different winding sections can be the same or different. FIG. 4 will be used to explain in detail the winding method in which a plurality of turns of the winding set 4 are wound around the annular body 31 to form three winding sections, and all the turns in each winding section are stacked on each other to form at least three winding layers.

Please refer to FIG. 4 in conjunction with FIG. 1 and FIG. 2, wherein FIG. 4 is a cross-sectional view of the magnetic assembly shown in FIG. 1. In FIG. 4, the number marked in each turn of the winding assembly 4 indicates the order in which the winding assembly 4 is wound on the annular body 31. For example, a number marked in a winding coil as 1 represents the first turn of the winding coil wound on the annular body 31, and a number marked in a winding coil as 2 represents the second turn of the winding coil wound on the annular body 31. As shown in FIG. 4, the three winding sections formed by the plurality of turns of the winding assembly 4 wound on the annular body 31 are respectively the first winding section 51, the second winding section 52, and the third winding section 53. In the first winding section 51, the first turn, the second turn, the third turn and the fourth turn of the winding assembly 4 are sequentially wound on the annular body 31 to form a first winding layer 61 in the first winding section 51, wherein the winding direction from the first turn wound on the annular body 31 to the fourth turn wound on the annular body 31 is a first direction X, for example, a clockwise direction. The fifth coil, the sixth coil, the seventh coil and the eighth coil of the winding set 4 are sequentially wound on the first winding layer 61 and constitute the second winding layer 62 in the first annular winding section 51, wherein the winding direction of the fifth coil wound on the annular body 31 toward the eighth coil wound on the annular body 31 is the second direction Y, for example, counterclockwise, wherein the second direction Y is opposite to the first direction X. The ninth turn, the tenth turn, the eleventh turn and the twelfth turn of the winding set 4 are sequentially wound on the second winding layer 62 and constitute the third winding layer 63 in the first annular winding section 51, wherein the winding direction of the ninth turn wound on the annular body 31 toward the twelfth turn wound on the annular body 31 is the first direction X.

As shown in FIG. 4, the first winding layer 61 in the first annular winding section 51 is located between the second winding layer 62 and the annular body 31, and the second winding layer 62 is located between the first winding layer 61 and the third winding layer 63. As can be seen from FIG. 4, all the coils in each of the three winding layers in the first annular winding section 51 are sequentially wound along the winding direction of the annular body 31, which is different from all the coils in another adjacent winding layer in the first annular winding section 51 being sequentially wound along the winding direction of the annular body. 31, for example, all the coils in the first winding layer 61 are sequentially along the winding direction (first direction X) of the annular body 31, which is different from all the coils in the second winding layer 62 being sequentially along the winding direction (second direction Y) of the annular body 31; all the coils in the second winding layer 62 are sequentially along the winding direction (second direction Y) of the annular body 31, which is different from all the coils in the third winding layer 63 being sequentially along the winding direction (first direction X) of the annular body 31. Furthermore, all the coils in the winding layer closest to the annular body 31 among the three winding layers in the first annular winding section 51 are sequentially wound along the winding direction of the annular body 31, which is the same as all the coils in the winding layer farthest from the annular body 31 are sequentially wound along the winding direction of the annular body 31. For example, all the coils in the first winding layer 61 are sequentially wound along the winding direction (first direction X) of the annular body 31, which is the same as all the coils in the third winding layer 63 are sequentially wound along the winding direction (first direction X) of the annular body 31.

In the second annular winding section 52, the thirteenth coil turn of the winding set 4 is connected to the twelfth coil turn in the first annular winding section 51 (the connection state is indicated by a dotted line in FIG. 4), and the thirteenth coil turn, the fourteenth coil turn, the fifteenth coil turn and the sixteenth coil turn of the winding set 4 are sequentially wound on the annular body 31 and constitute a first winding layer 64 in the second annular winding section 52, wherein the winding direction from the thirteenth coil turn wound on the annular body 31 to the sixteenth coil turn wound on the annular body 31 is a first direction X, for example, a clockwise direction. The seventeenth turn, the eighteenth turn, the nineteenth turn and the twentieth turn of the winding set 4 are sequentially wound on the first winding layer 64 and constitute the second winding layer 65 in the second annular winding section 52, wherein the winding direction of the seventeenth turn wound on the annular body 31 toward the twentieth turn wound on the annular body 31 is the second direction Y, for example, counterclockwise, wherein the second direction Y is opposite to the first direction X. The twenty-first turn, the twenty-second turn, the twenty-third turn and the twenty-fourth turn of the winding set 4 are sequentially wound on the second winding layer 65 and constitute the third winding layer 66 in the second annular winding section 52, wherein the winding direction of the twenty-first turn wound on the annular body 31 toward the twenty-fourth turn wound on the annular body 31 is the first direction X.

As shown in FIG. 4 , the first winding layer 64 in the second annular winding section 52 is located between the second winding layer 65 and the annular body 31, and the second winding layer 65 is located between the first winding layer 64 and the third winding layer 66. As can be seen from FIG. 4 , all the coils in each of the three winding layers in the second annular winding section 52 are sequentially wound along the winding direction of the annular body 31, which is different from all the coils in another adjacent winding layer in the second annular winding section 52 being sequentially wound along the winding direction of the annular body. 31, for example, all the coils in the first winding layer 64 are sequentially along the winding direction (first direction X) of the annular body 31, which is different from all the coils in the second winding layer 65 being sequentially along the winding direction (second direction Y) of the annular body 31; all the coils in the second winding layer 65 are sequentially along the winding direction (second direction Y) of the annular body 31, which is different from all the coils in the third winding layer 66 being sequentially along the winding direction (first direction X) of the annular body 31. Furthermore, all the coils in the winding layer closest to the annular body 31 among the three winding layers in the second winding section 52 are sequentially wound along the winding direction of the annular body 31, which is the same as all the coils in the winding layer farthest from the annular body 31 are sequentially wound along the winding direction of the annular body 31. For example, all the coils in the first winding layer 64 are sequentially wound along the winding direction (first direction X) of the annular body 31, which is the same as all the coils in the third winding layer 66 are sequentially wound along the winding direction (first direction X) of the annular body 31.

In the third winding section 53, the twenty-fifth turn of the winding set 4 is connected to the twenty-fourth turn of the winding set 4 in the second winding section 52 (the connection state is indicated by a dotted line in FIG. 4), and the twenty-fifth turn, the twenty-sixth turn, the twenty-seventh turn and the twenty-eighth turn of the winding set 4 are sequentially wound on the annular body 31 and constitute a first winding layer 67 in the third winding section 53, wherein the winding direction from the twenty-fifth turn wound on the annular body 31 to the twenty-eighth turn wound on the annular body 31 is a first direction X, for example, a clockwise direction. The twenty-ninth turn, the thirtieth turn, the thirty-first turn and the thirty-second turn of the winding set 4 are sequentially wound on the first winding layer 64 and constitute the second winding layer 68 in the third annular winding section 53, wherein the winding direction of the twenty-ninth turn wound on the annular body 31 toward the thirty-second turn wound on the annular body 31 is the second direction Y, for example, counterclockwise, wherein the second direction Y is opposite to the first direction X. The thirty-third turn, the thirty-fourth turn, the thirty-fifth turn and the thirty-sixth turn of the winding set 4 are sequentially wound on the second winding layer 68 and constitute the third winding layer 69 in the third annular winding section 53, wherein the winding direction of the thirty-third turn wound on the annular body 31 toward the thirty-sixth turn wound on the annular body 31 is the first direction X.

As shown in FIG. 4, the first winding layer 67 in the third annular winding section 53 is located between the second winding layer 68 and the annular body 31, and the second winding layer 68 is located between the first winding layer 67 and the third winding layer 69. As can be seen from FIG. 4, all the coils in each of the three winding layers in the third annular winding section 53 are sequentially wound along the winding direction of the annular body 31, which is different from all the coils in another adjacent winding layer in the second annular winding section 52 being sequentially wound along the winding direction of the annular body. 31, for example, all the coils in the first winding layer 67 are sequentially along the winding direction (first direction X) of the annular body 31, which is different from all the coils in the second winding layer 68 being sequentially along the winding direction (second direction Y) of the annular body 31; all the coils in the second winding layer 68 are sequentially along the winding direction (second direction Y) of the annular body 31, which is different from all the coils in the third winding layer 69 being sequentially along the winding direction (first direction X) of the annular body 31. Furthermore, all the coils in the winding layer closest to the annular body 31 among the three winding layers in the third winding section 53 are sequentially wound along the winding direction of the annular body 31, which is the same as all the coils in the winding layer farthest from the annular body 31 are sequentially wound along the winding direction of the annular body 31. For example, all the coils in the first winding layer 67 are sequentially wound along the winding direction (first direction X) of the annular body 31, which is the same as all the coils in the third winding layer 69 are sequentially wound along the winding direction (first direction X) of the annular body 31.

As shown in FIG. 4 , all the coils in the winding layer farthest from the annular body 31 (i.e., the third winding layer 63) among the three winding layers in the first annular interval 51 are sequentially wound along the winding direction of the annular body 31, similar to the winding layer farthest from the annular body 31 (i.e., the third winding layer 63) among the three winding layers in the second annular interval 52. All coils in the third winding layer 66 are sequentially along the winding direction of the annular body 31, and similarly, all coils in the winding layer farthest from the annular body 31 among the three winding layers in the third annular winding section 53 (i.e., the third winding layer 69) are sequentially along the winding direction of the annular body 31, that is, they are all in the first direction X.

In the above-mentioned embodiment, the winding group 4 of the magnetic component 2 constitutes three winding sections, and the number of winding layers in each section is three. Of course, in some embodiments, the number of winding sections formed by the multiple turns of each winding group 4 wound on the annular body 31 is not limited to three, but can be four or more. In some embodiments, the number of winding layers in each winding section is not limited to three, but can be five, seven or more, wherein the number of winding layers in each of the at least three winding sections except the last winding section must be an odd number. In addition, the number of winding layers in each surrounding interval can be the same or different.

In some embodiments, the last winding section in the winding section, such as the third winding section 53 in FIG. 4, may include only a single winding layer, that is, the third winding section 53 may include only the first winding layer 67. As can be seen from FIG. 4, all the coils in the first winding layer 67 of the third winding section 53 are sequentially arranged along the winding direction of the annular body 31, which is the same as the second winding section. All coils in the winding layer farthest from the annular body 31 among the three winding layers in 52 (i.e., the third winding layer 66) are sequentially along the winding direction of the annular body 31, and are similar to all coils in the winding layer farthest from the annular body 31 among the three winding layers in the first annular interval 51 (i.e., the third winding layer 63) are sequentially along the winding direction of the annular body 31, that is, they are all in the first direction X.

Of course, in some embodiments, the last winding section in the winding sections, such as the third winding section 53 in FIG. 4, may include only two winding layers, that is, the third winding section 53 may include only the first winding layer 67 and the second winding layer 68. As can be seen from FIG. 4, all the coils in the second winding layer 68 of the third winding section 53 are sequentially arranged along the winding direction of the annular body 31, which is different from the winding layer in FIG. All coils in the winding layer farthest from the annular body 31 among the three winding layers in the second annular winding section 52 (i.e., the third winding layer 66) are sequentially along the winding direction of the annular body 31, and are different from all coils in the winding layer farthest from the annular body 31 among the three winding layers in the first annular winding section 51 (i.e., the third winding layer 63) are sequentially along the winding direction of the annular body 31, that is, they are all in the second direction Y. Of course, the last annular winding section in the annular winding section may also include more than two winding layers, such as any even number of winding layers.

Please refer to FIG. 5, which is a comparison diagram of the impedance and bandwidth of the magnetic component shown in FIG. 1 and the magnetic component using the traditional stacking winding method. FIG. 5 shows the impedance and bandwidth schematic lines of the magnetic component using the traditional stacking winding method, and the impedance and bandwidth schematic lines of the magnetic component 2 shown in FIG. 1, respectively. It can be clearly seen that the peak value of the impedance of the magnetic component using the traditional stacking winding method is about 35000Ω, while the peak value of the impedance of the magnetic component 2 of this embodiment is about 41000Ω, wherein the peak value of the impedance of the magnetic component 2 of this embodiment is significantly greater than the peak value of the impedance of the magnetic component using the traditional stacking winding method. When the impedance is greater than or equal to 20000Ω, the bandwidth of the magnetic component 2 of this embodiment is significantly greater than the bandwidth of the magnetic component using the traditional layer winding method.

Please refer to FIG. 6 , which is a cross-sectional view of the magnetic component of the second embodiment of the present invention. In some embodiments, at least two winding groups of the magnetic component are not limited to being intertwined with each other, but can be wound around the annular body in a double-wire parallel winding manner. As shown in FIG. 6 , the at least two winding groups of the magnetic component 2a of this embodiment include a first winding 71 and a second winding 72. The blank circle in FIG. 6 represents a cross-section of the first winding 71, and the dotted circle represents a cross-section of the second winding 72. The first winding 71 and the second winding 71 are wound around the annular body 31 in a manner of forming a group side by side, and the winding method of a group of the first winding 71 and the second winding 71 is similar to the winding method of the winding group 4 of the first embodiment, which will not be repeated here. Of course, in some embodiments, the number of the winding sections formed by the plurality of turns of each first winding 71 and each second winding 72 wound around the annular body 31 is not limited to three, but may be four or more. In some embodiments, the number of winding layers in each winding section is not limited to three, but may be an odd number, but may be five, seven or more. In addition, the number of winding layers in each winding section may be the same or different.

In summary, the magnetic component of the present invention uses two windings to be wound on the annular body of the magnetic core and forms at least three winding sections, wherein all the coils in each of the at least three winding sections except the last winding section constitute at least three winding layers stacked on each other, and the number of at least three winding layers in each of the at least three winding sections except the last winding section is an odd number. Compared with the magnetic component using the traditional stacking winding method, the magnetic component of the present invention can have the advantages of increasing impedance value and increasing bandwidth by the design of the winding method of the winding. In addition, at least two windings of the magnetic component of the present invention are composed of completely insulated wires, so that at least two windings can be intertwined with each other or stacked on the annular body. Therefore, compared with the magnetic component using the traditional stacking winding method that requires the installation of an isolation sheet, the magnetic component of the present invention does not need to be additionally installed with an isolation sheet, thereby achieving the effect of reducing costs.

1: Power module AC: AC power L: Common mode filter inductor 2, 2a: Magnetic components 3: Magnetic core 31: Ring body 311: Upper surface 312: Lower surface 313: Outer ring side 314: Inner ring side 32: Hollow area 4: Winding 51: First winding interval 61: First winding layer 62: Second winding layer 63: Third winding layer X: First direction Y: Second direction 52: Second winding interval 64: First winding layer 65: Second winding layer 66: Third winding layer 53: Third winding interval 67: First winding layer 68: Second winding layer 69: Third winding layer 71: First winding line 72: Second winding line 81, 84, 87: First winding layer 82, 85, 88: Second winding layer 83, 86, 89: Third winding layer

FIG. 1 is a schematic diagram of the structure of the magnetic component of the first embodiment of the present invention. FIG. 2 is a schematic diagram of the exploded structure of the magnetic component shown in FIG. 1. FIG. 3 is an equivalent circuit structure diagram of the power module to which the magnetic component shown in FIG. 1 is applied. FIG. 4 is a cross-sectional view of the magnetic component shown in FIG. 1. FIG. 5 is a comparison diagram of the impedance and bandwidth of the magnetic component shown in FIG. 1 and the magnetic component using the traditional layer winding method. FIG. 6 is a cross-sectional view of the magnetic component of the second embodiment of the present invention.

2: Magnetic components

3: Magnetic core

313: Outer ring side

32: Hollow area

4: Winding

51: First ring interval

61: First winding layer

62: Second winding layer

63: The third winding layer

X: First direction

Y: Second direction

52: Second ring interval

64: First winding layer

65: Second winding layer

66: The third winding layer

53: Third ring interval

67: First winding layer

68: Second winding layer

69: Third winding layer

Claims (10)

A magnetic component comprises: a magnetic core having an annular body and a hollow area; and at least two winding groups, each of which has a plurality of turns, each of which passes through the hollow area and is wound around the annular body, and the plurality of turns of the at least two winding groups are wound around the annular body to form at least three winding sections, and all the turns in each of the at least three winding sections except the last winding section constitute at least three winding layers stacked on each other, and the number of the at least three winding layers in each of the at least three winding sections except the last winding section is an odd number. A magnetic component as claimed in claim 1, wherein all the coils of each winding layer in each of the at least three winding sections except the last winding section are sequentially arranged along the winding direction of the annular body, which is different from all the coils of another adjacent winding layer in the same winding section. All the coils of the winding layer closest to the annular body in the at least three winding layers of each of the at least three winding sections except the last one are sequentially arranged along the winding direction of the annular body, which is the same as all the coils of the winding layer farthest from the annular body in the same winding section are sequentially arranged along the winding direction of the annular body. A magnetic component as described in claim 2, wherein all the coils in the last of the at least three winding intervals constitute at least one winding layer, and the number of the at least one winding layer in the last of the at least three winding intervals is an odd number, wherein the number of the at least one winding layer in the last of the at least three winding intervals is an odd number. All the coils of the winding layer farthest from the annular body in at least one winding layer are sequentially arranged along the winding direction of the annular body, which is the same as all the coils of the winding layer farthest from the annular body in the at least three winding layers in each of the at least three winding sections except the last one are sequentially arranged along the winding direction of the annular body. A magnetic component as described in claim 2, wherein all the coils in the last of the at least three winding intervals constitute at least two winding layers, and the number of the at least two winding layers in the last of the at least three winding intervals is an even number, wherein the last of the at least three winding intervals has an even number of winding layers. All the coils of the winding layer farthest from the annular body among the at least two winding layers are sequentially arranged along the winding direction of the annular body, while all the coils of the winding layer farthest from the annular body among the at least three winding layers in each of the at least three winding intervals except the last one are sequentially arranged along the winding direction of the annular body. The magnetic component as claimed in claim 1, wherein the at least three winding layers in each of the winding sections include a first winding layer, a second winding layer and a third winding layer, wherein the first winding layer is formed by the winding layer closest to the annular body in the winding section, and the third winding layer is formed by the winding layer farthest from the annular body in the winding section. The second winding layer is stacked between the first winding layer and the third winding layer, wherein the winding direction of the first winding layer along the annular body is the same as the winding direction of the third winding layer along the annular body, and the winding direction of the second winding layer along the annular body is different from the winding direction of the first winding layer along the annular body. A magnetic component as described in claim 1, wherein the at least three winding sections include a first winding section, a second winding section and a third winding section, and the first winding section, the second winding section and the third winding section are sequentially wound around the annular body of the magnetic core, wherein the winding layer in the first winding section farthest from the annular body is connected to the winding layer in the second winding section closest to the annular body, and the winding layer in the second winding section farthest from the annular body is connected to the winding layer in the third winding section closest to the annular body. A magnetic component as described in claim 1, wherein the withstand voltage of at least two sets of windings is greater than 1.5 kV. A magnetic component as described in claim 1, wherein the at least two groups of windings are intertwined with each other to be wound around the annular body. A magnetic component as described in claim 1, wherein the at least two groups of windings include a first winding and a second winding, wherein the first winding and the second winding are wound around the annular body in a double-wire parallel winding manner. A magnetic component as described in claim 1, wherein each of the windings is composed of a completely insulating wire.

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