TWI756049B - Magnetic device - Google Patents

Abstract

A magnetic device is provided, including an upper magnetic core, a lower magnetic core, a coil, and a permeability member, wherein the permeability member is disposed between the upper magnetic core and the lower magnetic core. The coil is enclosed by the permeability member, and the permeability member is in contact with the upper magnetic core and the lower magnetic core.

Description

Magnetic device

The present invention relates to a magnetic device. More specifically, the present invention relates to a magnetic device having a magnetically permeable element.

Many electronic devices have components that include coils and magnetic components, such as inductors or voltages. To avoid short circuits between the coils and the magnetics, and to comply with safety regulations, the coils and the magnetics are usually separated by an air gap. However, such a structure will increase the loss, thereby making the use efficiency of the parts worse. Therefore, how to solve the aforementioned problems has become an important issue.

The invention provides a magnetic device, comprising an upper magnetic core, a lower magnetic core, a coil, and a magnetic conductive element, wherein the magnetic conductive element is arranged between the upper magnetic core and the lower magnetic core. Furthermore, the magnetic conductive element further covers the coil and is in contact with the upper magnetic core and the lower magnetic core.

In some embodiments of the present invention, the initial magnetic permeability of the aforementioned magnetically permeable element is greater than the initial magnetic permeability of air. The initial magnetic permeability of the upper magnetic core is greater than the initial magnetic permeability of the magnetically permeable element. The initial permeability of the lower magnetic core is greater than that of the magnetically permeable element.

In some embodiments of the present invention, the aforementioned magnetic conductive element is formed by mixing adhesive and powder with high magnetic permeability.

In some embodiments of the present invention, the aforementioned upper magnetic core and the lower magnetic core are connected to form an accommodating space between the upper magnetic core and the lower magnetic core, and the magnetic conductive element is disposed in the accommodating space. The accommodating space is formed between the two side pillars, and at least part of the outline of each side pillar is substantially the same as at least part of the outline of the magnetic conductive element. In some embodiments, the magnetic conductive element fills the accommodating space.

In some embodiments of the present invention, the upper magnetic core has a first protruding portion, the lower magnetic core has a second protruding portion, the first protruding portion is aligned with the second protruding portion, and the magnetic conductive element surrounds the first protruding portion Outlet and second protrusion. A portion of the magnetically conductive element is located between the coil and the first protrusion.

In some embodiments of the present invention, the aforementioned coil has an annular structure, the annular structure surrounds a hollow portion, and the magnetic conductive element fills the hollow portion.

In some embodiments of the present invention, the aforementioned lower magnetic core includes a plurality of pins.

100: Upper magnetic core

110: Top plate

111: First surface

120: jamb

121: Concave surface

130: The first protrusion

200: Lower core

210: Bottom plate

211: Second Surface

220: jamb

221: Concave Surface

230: Second protrusion

300: Coil

310: hollow part

400: Magnetically conductive element

M1: Magnetic device

M2: Magnetic device

M3: Magnetic device

R: accommodation space

W: reel

W1: pin

W2: pin

The embodiments of the present invention can be better understood according to the following detailed description and the accompanying drawings. It should be noted that, in accordance with standard practice in the industry, the various components in the drawings are not necessarily drawn to scale. In fact, the dimensions of various components may be arbitrarily enlarged or reduced for clarity of illustration.

FIG. 1 is a schematic diagram showing a magnetic device according to an embodiment of the present invention.

Fig. 2 is an exploded view showing a magnetic device according to an embodiment of the present invention.

Fig. 3 is a cross-sectional view taken along the direction A-A in Fig. 1 .

FIG. 4 is a cross-sectional view taken along the direction B-B in FIG. 1 .

FIG. 5 is a schematic diagram showing a magnetic device according to another embodiment of the present invention.

Fig. 6 is an exploded view showing a magnetic device according to another embodiment of the present invention.

FIG. 7 is a cross-sectional view taken along the C-C direction in FIG. 5 .

FIG. 8 is a schematic diagram showing a magnetic device according to another embodiment of the present invention.

The magnetic device of the present invention will be described below. It can be readily appreciated, however, that the present invention provides many suitable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments disclosed are merely illustrative of particular ways to use the invention, and are not intended to limit the scope of the invention.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It is to be understood that these terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the relevant art and the background or context of the present invention. should not be read in an idealized or overly formal manner unless specifically defined herein.

The following disclosure of this specification is to describe specific examples of various components and their arrangement in order to simplify the description of the invention. Of course, these specific examples are not intended to limit the present invention. For example, if the following disclosure of this specification describes that a first feature is formed on or over a second feature, it means that it includes an embodiment in which the first feature and the second feature are formed in direct contact with each other. , and also includes embodiments in which additional features may be formed between the first and second features, so that the first and second features may not be in direct contact. Furthermore, for convenience in describing the relationship of one feature to another feature in the drawings, spatially relative terms such as "below", "below", "below", "above", "above", and the like may be used. terms, etc. In addition to the orientation depicted in the drawings, spatially relative terms encompass different orientations of the device in use or operation. The device may also be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptions used herein interpreted accordingly.

Please refer to FIG. 1 and FIG. 2 first. The magnetic device M1 according to an embodiment of the present invention mainly includes an upper magnetic core 100 , a lower magnetic core 200 , a coil 300 , and a magnetic conductive element 400 . The upper magnetic core 100 and the lower magnetic core 200 can be combined with each other to form an accommodating space R therebetween, and the aforementioned coil 300 and the magnetic conductive element 400 can be accommodated in the accommodating space R. In this embodiment, the magnetic device M1 may be an inductor for reducing ripple, removing noise, reducing electromagnetic interference (EMI), and/or converting power. Magnetic device M1 can be applied to many In different electronic devices, such as power supplies, motherboards, modems, etc., but not limited to this.

The upper magnetic core 100 has an E-shaped structure. In detail, the upper magnetic core 100 may have a top plate 110 , two side pillars 120 (first side pillars), and a first protruding portion 130 . The two side pillars 120 are connected to the top plate 110 and are respectively located at two ends of a first surface 111 of the top plate 110 . The first protruding portion 130 is disposed at the center of the top plate 110 and away from the aforementioned side pillars 120 . In this embodiment, the first protruding portion 130 has a cylindrical structure, and when the upper magnetic core 100 and the lower magnetic core 200 are combined with each other, the two side pillars 120 and the first protruding portion 130 are both directed toward the lower magnetic core. The core 200 extends.

The lower magnetic core 200 also has an E-shaped structure. In detail, the lower magnetic core 200 may have a bottom plate 210 , two side pillars 220 (second side pillars), and a second protruding portion 230 . The two side pillars 220 are connected to the bottom plate 210 and are respectively located at two ends of a second surface 211 of the bottom plate 210 . The second protruding portion 230 is disposed in the center of the bottom plate 210 and separated from the aforementioned side pillars 220 . In this embodiment, the second protruding portion 230 has a cylindrical structure, and when the upper magnetic core 100 and the lower magnetic core 200 are combined with each other, the two side posts 220 and the second protruding portion 230 are both directed toward the upper magnetic core. The core 100 extends, and the accommodating space R is formed between the side pillars 120 and 220 .

In this embodiment, the cross-sectional shape and size of the first protruding portion 130 are substantially the same as the cross-sectional shape and size of the second protruding portion 230, and when the upper magnetic core 100 and the lower magnetic core 200 are combined with each other, the first The protruding parts 130 are aligned and contact the second protruding parts 230 , so that a column body located in the accommodating space R can be formed.

It should be noted that the above-mentioned upper magnetic core 100 and lower magnetic core 200 are made of materials with high initial magnetic permeability (μi), for example, materials with initial magnetic permeability ranging from 8,000 to 10,000. For example, the upper magnetic core 100 and the lower magnetic core 200 may include iron, manganese, zinc, amorphous metals, combinations thereof, or alloys thereof, etc., but are not limited thereto. In this embodiment, the top plate 110 , the side posts 120 and the first protruding parts 130 of the upper magnetic core 100 are formed in one piece, and the bottom plate 210 , the side posts 220 and the second protruding parts of the lower magnetic core 200 230 is also formed in one piece.

FIG. 3 is a cross-sectional view of the magnetic device M1 taken along the A-A direction, and FIG. 4 is a cross-sectional view of the magnetic device M1 taken along the B-B direction. As shown in FIG. 1 to FIG. 4 , when the magnetic device M1 is assembled, the coil 300 and the magnetic conductive element 400 will be accommodated in the accommodating space R, surrounded by the first protruding portion 130 and the second protruding portion 400 . The column formed by the portion 230. The coil 300 may be covered by the magnetic conductive element 400 , and the magnetic conductive element 400 may be in contact with the upper magnetic core 100 and the lower magnetic core 200 .

The magnetic conductive element 400 may include powder and adhesive with high magnetic permeability. The user can mix the powder with high magnetic permeability and the adhesive, then coat the entire coil 300 by injection molding, and then heat the temperature (for example, to 130° C. to 150° C.) and bake to solidify the mixture of the powder and the adhesive. The magnetically conductive element 400 covering the coil 300 may be formed. The initial magnetic permeability of the magnetically permeable element 400 formed in the foregoing manner may be greater than the initial magnetic permeability of air (the initial magnetic permeability of air is about 1), for example, may be between 2000-3000.

In this embodiment, when the magnetic conductive element 400 covering the coil 300 is disposed in the accommodating space R, the magnetic conductive element 400 is disposed between the two side posts 120 of the upper magnetic core 100 . A concave curvature may be formed on the surface of each side post 120 facing the magnetic conductive element 400 surface 121 , and the contour of the concave curved surface 121 may correspond to the contour of the magnetically conductive element 400 . Therefore, when the magnetic conductive element 400 is disposed in the accommodating space R, it can contact the concave curved surface 121 of the side post 120 and be positioned by the concave curved surface 121 .

Similarly, when the magnetic conductive element 400 covering the coil 300 is disposed in the accommodating space R, the magnetic conductive element 400 is disposed between the two side pillars 220 of the lower magnetic core 200 . A concave curved surface 221 may be formed on the surface of each side pillar 220 facing the magnetic conductive element 400 , and the contour of the concave curved surface 221 may correspond to the contour of the magnetic conductive element 400 . Therefore, when the magnetic conductive element 400 is disposed in the accommodating space R, it can contact the concave curved surface 221 of the side post 220 and be positioned by the concave curved surface 221 .

In addition, when the upper magnetic core 100 and the lower magnetic core 200 are combined with each other, the distance between the top plate 110 and the bottom plate 210 is approximately the same as the thickness of the magnetic conductive element 400 . The element 400 will also contact the top plate 110 of the upper core 100 and the bottom plate 210 of the lower core 200 at the same time.

Furthermore, the coil 300 has an annular structure, so the annular structure will surround a hollow portion 310 , and the first protruding portion 130 and the second protruding portion 230 can pass through the hollow portion 310 . Since the magnetic conductive element 400 completely covers the coil 300, a part of the magnetic conductive element 400 is located between the coil 300 and the first protrusion 130/second protrusion 230, and can contact the first protrusion 130 and the The second protruding portion 230 .

Through the foregoing structure, the air gaps between the coil 300 and the upper magnetic core 100 and between the coil 300 and the lower magnetic core 200 can be reduced, thereby increasing the inductance value and reducing the ripple on the circuit.

In some embodiments, the magnetic conductive element 400 can fill the accommodation space R to increase the contact area between the magnetic conductive element 400 and the upper magnetic core 100 and the lower magnetic core 200 , thereby increasing the inductance value and enhancing the positioning effect.

Please refer to FIGS. 5 to 7 , in another embodiment of the present invention, the magnetic device M2 mainly includes an upper magnetic core 100 , a lower magnetic core 200 , a coil 300 , and a magnetic conductive element 400 . The structure and configuration of the magnetic device M2 are substantially the same as those of the magnetic device M1, so the same parts will not be repeated.

Different from the magnetic device M1, the upper magnetic core 100 and the lower magnetic core 200 of the magnetic device M2 each have a C-shaped structure, so the magnetic device M2 will not include the first protrusions 130 and 130 in the accommodating space R. The second protruding portion 230 . The coil 300 has an annular structure and a hollow portion 310 surrounded by the annular structure, and the magnetic conductive element 400 will fill the aforementioned hollow portion 310 .

Referring to FIG. 8 , in another embodiment of the present invention, the magnetic device M3 mainly includes an upper magnetic core 100 , a lower magnetic core 200 , a coil 300 , and a magnetic conductive element 400 . The structure and configuration of the magnetic device M3 are substantially the same as those of the magnetic device M1, so the same parts will not be repeated. In this embodiment, the magnetic device M3 can be a transformer. When the current flows into the magnetic device M3, the magnetic device M3 can output currents with different voltages through electromagnetic induction.

Different from the magnetic device M1, the magnetic device M3 further includes a bobbin W, and the first protruding portion 130 and the second protruding portion 230 of the upper magnetic core 100 and the lower magnetic core 200 pass through the bobbin W. In the through hole in the center, the magnetic conductive element 400 is arranged around the outer ring surface of the winding portion of the bobbin W, and the bobbin W is respectively provided with one or more pins W1, W2, the end of the coil 300 in the magnetic conductive element 400 can pass through the magnetic conductive element 400 and be wound on the pins W1 and W2.

In summary, the present invention provides a magnetic device comprising an upper magnetic core, a lower magnetic core, a coil, and a magnetic conductive element, wherein the magnetic conductive element is disposed between the upper magnetic core and the lower magnetic core. Furthermore, the magnetic conductive element further covers the coil and is in contact with the upper magnetic core and the lower magnetic core. With the aforementioned structure of the magnetic device, the inductance value of the magnetic device can be effectively increased, and the surge on the circuit can be reduced. Furthermore, since there is no need for additional positioning elements to position the coil, the complexity of the manufacturing process can be reduced, and the overall volume of the magnetic device can be reduced, which is beneficial to the miniaturization of the magnetic device.

Although the embodiments of the present invention and their advantages have been disclosed above, it should be understood that those skilled in the art can make changes, substitutions and modifications without departing from the spirit and scope of the present invention. In addition, the protection scope of the present invention is not limited to the process, machine, manufacture, material composition, device, method and steps in the specific embodiments described in the specification, and any person with ordinary knowledge in the technical field can learn from the present disclosure. It is understood that processes, machines, manufactures, compositions of matter, devices, methods and steps developed in the present or in the future can be used in accordance with the present invention as long as they can perform substantially the same functions or achieve substantially the same results in the embodiments described herein. Therefore, the protection scope of the present invention includes the above-mentioned process, machine, manufacture, composition of matter, device, method and steps. In addition, each claimed scope constitutes a separate embodiment, and the protection scope of the present invention also includes the combination of each claimed scope and the embodiments.

Although the present invention is disclosed in the foregoing several preferred embodiments, it is not intended to limit the present invention. Those with ordinary knowledge in the technical field to which the present invention pertains, Minor changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention should be determined by the scope of the appended patent application. Furthermore, each claimable scope constitutes a separate embodiment, and various claims and combinations of embodiments are intended to be within the scope of the present disclosure.

100: Upper magnetic core

110: Top plate

111: First surface

120: jamb

130: The first protrusion

200: Lower core

210: Bottom plate

211: Second Surface

220: jamb

230: Second protrusion

300: Coil

400: Magnetically conductive element

M1: Magnetic device

Claims (8)

A magnetic device, comprising: an upper magnetic core, including a top plate and two first side posts, wherein the first side posts are connected to the top plate and are respectively located at both ends of a first surface of the top plate; a lower magnetic core, It includes a bottom plate and two second side pillars, wherein the second side pillars are connected to the bottom plate and are respectively located at two ends of a second surface of the bottom plate; a coil; and a magnetic conductive element arranged on the upper magnetic core and the lower magnetic core, wherein the magnetic conductive element covers the coil, and the initial magnetic permeability of the upper magnetic core and/or the initial magnetic permeability of the lower magnetic core is greater than the initial magnetic permeability of the magnetic conductive element , wherein the upper magnetic core is connected with the lower magnetic core to form an accommodating space between the upper magnetic core and the lower magnetic core, and the magnetic conductive element is arranged in the accommodating space, wherein the accommodating space is formed between the first side pillars and the second side pillars, and at least part of the outline of each first side pillar is substantially the same as at least part of the outline of the magnetic conductive element, and each second side At least part of the outline of the column is substantially the same as at least part of the outline of the magnetically conductive element, wherein the magnetically conductive element fills the accommodating space. The magnetic device of claim 1, wherein the magnetic conductive element contacts the upper magnetic core and the lower magnetic core. The magnetic device of claim 1, wherein the magnetic conductive element is formed by mixing adhesive and powder with high magnetic permeability. The magnetic device of claim 1, wherein the upper magnetic core has a first protruding portion, the lower magnetic core has a second protruding portion, the first protruding portion is aligned with the second protruding portion, and the guide A magnetic element surrounds the first protrusion and the second protrusion. The magnetic device of claim 4, wherein a portion of the magnetically conductive element is located between the coil and the first protruding portion. The magnetic device of claim 1, wherein the coil has an annular structure, the annular structure surrounds a hollow portion, and the magnetic conductive element fills the hollow portion. The magnetic device of claim 6, wherein the upper magnetic core has a first protruding portion, the lower magnetic core has a second protruding portion, and the first protruding portion and the second protruding portion pass through the hollow part, and the magnetic conductive element contacts the first protruding part and the second protruding part. The magnetic device of claim 1, wherein the magnetic device further comprises a bobbin, the bobbin includes a plurality of pins, and the magnetic conductive element is annularly arranged on the bobbin.

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