WO2014205164A1 - Magnetic components and rolling manufacturing method - Google Patents

Magnetic components and rolling manufacturing method Download PDF

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Publication number
WO2014205164A1
WO2014205164A1 PCT/US2014/043093 US2014043093W WO2014205164A1 WO 2014205164 A1 WO2014205164 A1 WO 2014205164A1 US 2014043093 W US2014043093 W US 2014043093W WO 2014205164 A1 WO2014205164 A1 WO 2014205164A1
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WO
WIPO (PCT)
Prior art keywords
magnetic
core
coil
flexible
magnetic core
Prior art date
Application number
PCT/US2014/043093
Other languages
French (fr)
Inventor
Yuexin LIU
Original Assignee
Liu Yuexin
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Filing date
Publication date
Application filed by Liu Yuexin filed Critical Liu Yuexin
Publication of WO2014205164A1 publication Critical patent/WO2014205164A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/06—Fixed inductances of the signal type  with magnetic core with core substantially closed in itself, e.g. toroid
    • H01F17/062—Toroidal core with turns of coil around it
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/06—Fixed inductances of the signal type  with magnetic core with core substantially closed in itself, e.g. toroid
    • H01F2017/065—Core mounted around conductor to absorb noise, e.g. EMI filter
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/08—Cores, Yokes, or armatures made from powder

Definitions

  • TITLE MAGNETIC COMPONENTS AND ROLLING MANUFACTURING METHOD
  • This invention pertains to the design and manufacturing of electric or electronic devices and more particularly to the design and manufacturing of electric or electronic devices that include a magnetic component structure composed of at least one magnetic core to provide a magnetic path for the magnetic flux and at least one conductive coil winding to provide magneto-motive forces.
  • the growing interest on the small size yet high power density electronic devices challenges the design and manufacturing of the magnetic components.
  • the core size and the coil size must be reduced to reduce the overall structure size of the magnetic components despite an increased current being carried by the magnetic components.
  • the manufacturing processes also need to be optimized and simplified to reduce the cost while improving the performance. Many efforts have been dedicated to optimize the core shapes to maximize the usage of the core material. Many efforts have also been contributed to simplify the manufacturing processes to reduce the manufacturing cost and improve the competitiveness.
  • Conventional magnetic components typically include a magnetic core and a winding or a coil wound on the magnetic core.
  • the core may be fabricated from magnetic materials and is typically formed at certain shapes prior winding.
  • the core may include over one core pieces and the shapes may include I core, EE core, U core, toroidal core, pot core, T core, and other shapes.
  • the core may be bonded with epoxy, epoxy combined with glass bead, or other composite magnetic materials.
  • the coils or windings are fabricated from a conductive wire such as a magnet wire or a tin coated copper wire. The coils are further fabricated by wrapping the wire around a core piece completely formed to a certain shape beforehand.
  • This invention generally relates to the design and manufacturing of electric or electronic devices that include a magnetic component structure composed of at least one magnetic core to provide a magnetic path for the magnetic flux and at least one conductive coil winding to provide magneto-motive forces.
  • a conductive coil or coils are wound on a flexible magnetic core.
  • a magnetic path is then formed by rolling the flexible magnetic core with the wound coil or coils to a closed or gapped loop which can be formed into variety of shapes such as a toroidal shape.
  • the conductive coils can be made of including but not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, triple insulation wires, and cables.
  • the coil or coils can be directly wound on the flexible magnetic core or indirectly wound on the flexible magnetic core with the use of a fixture.
  • the fixture is used either together with or separately from the flexible magnetic core.
  • the fixture guides the winding or windings on the flexible magnetic core.
  • the indirect method winds the coil or coils on the fixture first and then shifts the coil or coils to the flexible magnetic core.
  • the flexible magnetic core is made of a flexible magnetic sheet or sheets.
  • the flexible magnetic sheet or sheets has or have predefined thickness, width, and length and has or have a relatively high electrical resistivity, and the flexible magnetic sheet or sheets can be but is not or are not limited to rectangular in shape.
  • the magnetic sheet is fabricated by magnetic materials, such as magnetic powder materials or ferrite materials combined with flexible insulation materials, such as polymer or rubber. With the rolled structure of the magnetic sheet or sheets, a magnetic path is formed to facilitate the circulation of the magnetic flux.
  • the rolling method enables the flexible magnetic core with the wound coil or coils to form different shapes.
  • An encapsulation casing can be included to secure the coil winding or windings and the flexible magnetic core.
  • the conductive coil or coils can include a plurality of turns.
  • the conductive coil or coils can also be directly-fed-through wires, and the coils can be contained in a cable or a plurality of cables.
  • a variety of magnetic components including but not limited to axial inductors, radial inductors, common mode inductors, transformers, noise suppression filters, and low profile packed inductors can be manufactured by using the magnetic component structure and the manufacturing method.
  • Such magnetic components may be power management devices in electrical systems and electronic devices in electronics, and such magnetic components have low electromagnetic emission and interference due to the looping nature of the magnetic flux path and in the meantime maintain high performance and small size due to the extensible nature of the flexible magnetic core.
  • Figure 1 discloses a structure and a manufacturing step of winding a coil on a flexible magnetic core for one embodiment of the magnetic components as an axial inductor.
  • Figure 2 discloses a structure and a manufacturing step of rolling a wound core to form a looped magnetic flux path for one embodiment of the magnetic components as an axial inductor.
  • Figure 3 discloses a structure of a rolled assembly of a coil and a flexible magnetic core with a portion of the core overlapped and two end wires on the opposite sides for one embodiment of the magnetic components as an axial inductor.
  • Figure 4 discloses a completed assembly of coil, core and encapsulation casing for one embodiment of the magnetic components as an axial inductor.
  • Figures 5 discloses a structure of a rolled assembly of two coils and one flexible magnetic core with a portion of the core overlapped for another embodiment of the magnetic components as a common mode inductor.
  • Figures 6 discloses a completed assembly of coils and core for another embodiment of the magnetic components as a common mode inductor.
  • Figure 7 discloses a rolled assembly of one embodiment of the magnetic components as one noise suppression filter.
  • Figure 8 discloses a rolled assembly of one embodiment of the magnetic components as another noise suppression filter.
  • Figures 9 discloses a structure of a rolled assembly of a coil and a flexible magnetic core with a portion of the core overlapped and two end wires on the same side for another embodiment of the magnetic components as a radial inductor.
  • Figure 10 discloses a completed assembly of coil, core and encapsulation casing for one embodiment of the magnetic components as a radial inductor.
  • Figures 1 1 discloses a structure of a rolled assembly of a coil and a flexible magnetic core with a portion of the core overlapped and two end wires on the opposite sides for another embodiment of the magnetic components as a low profile packed inductor.
  • Figure 12 discloses an assembly of coil, core and encapsulation casing for one embodiment of the magnetic components as a low profile packed inductor.
  • Figure 13 shows a completed assembly of coil, core, encapsulation casing and surface mount options for one embodiment of the magnetic components as a low profile packed inductor.
  • DESCRIPTION OF THE PREFERRED EMBODIMENTS This invention discloses the designs of magnetic components and the methods to manufacture such magnetic components. Preliminary experiment results confinn that higher performance and smaller footprint can be achieved by using these unique and simple designs and manufacturing methods than the traditional designs and manufacturing processes.
  • AXIAL INDUCTORS DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • Figures 1-4 disclose a magnetic component as an axial power inductor.
  • the axial power inductor comprises a ilexible magnetic core 102 and a coil 104.
  • the coil 104 includes a first end 100, a second end 101, and a plurality of turns wrapped on the flexible magnetic core.
  • the coil can be fabricated from materials that can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, and triple insulation wires.
  • the first end 100 and the second end 101 can be the same material as the coil winding or different material. Both 100 and 101 can connect to the electrical circuit to receive and deliver electrical current.
  • the flexible core comprises at least one flexible magnetic sheet.
  • the magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials.
  • the magnetic sheet which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack.
  • the magnetic sheet further has a relatively high electrical resistivity.
  • Figures 1 -4 also disclose the manufacturing process of this embodiment.
  • wind a coil or winding on a flexible magnetic core composed of at least one flexible magnetic sheet This step is illustrated in the Figure 1.
  • the coil can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture.
  • the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed.
  • the coil can be wound on a fixture first and then be shifted onto the flexible magnetic core.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled magnetic core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized.
  • the core overlapping portion is directly contacted by the sheet material.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll through a small portion of a tape or a similar low magnetic conductive material to create a gap in the magnetic flux path.
  • the flexible magnetic core is rolled for a plurality of rolls.
  • Figure 4 illustrates the finished encapsulated axial power inductor.
  • 105 in figure 4 shows the encapsulated coil and core, and the first end 100 and the second end 101 , which are on the opposite sides of the secure encapsulation, can be stripped and then tinned before or after these process steps.
  • COMMON MODE INDUCTORS COMMON MODE INDUCTORS
  • Figures 5-6 disclose a magnetic component as a common mode inductor.
  • the common mode inductor comprises a flexible magnetic core 206 and two coils, coil 204 and coil 205.
  • the coil 204 further comprises a first end 202, a second end 203, and a single turn or a plurality of turns wrapped on the flexible magnetic core.
  • the coil 205 further comprises a first end 200, a second end 201, and a single turn or a plurality of turns wrapped on the flexible magnetic core.
  • the materials for fabricating the coils can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, and triple insulation wires.
  • the first end 200 and the second end 201 of the coil 205 can be the same material as the coil 205 or different material, and can connect to the electrical circuit to receive and deliver current.
  • the first end 202 and the second end 203 of the coil 204 can be the same material as the coil 204 or different material, and can connect to the electrical circuit to receive and deliver current.
  • the flexible magnetic core comprises at least one flexible magnetic sheet.
  • the magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials.
  • the magnetic sheet which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack.
  • the magnetic sheet further has a relatively high electrical resistivity.
  • This embodiment can also be functioned as a transformer by configuring one coil as the electrical transformer primary winding and another coil as the electrical transformer secondary winding.
  • the coils can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture.
  • the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed.
  • the coils can be wound on a fixture first and then be shifted onto the flexible magnetic core.
  • the combined object of the coils and the flexible magnetic core will be rolled together.
  • ways in rolling the wound flexible magnetic core which include but are not limited to the following two examples.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized.
  • the core overlapping portion is directly contacted by the sheet material.
  • the wound flexible magnetic core is rolled for a plurality of rolls.
  • Figure 6 illustrates the finished encapsulated common mode inductor, and component 207 in figure 6 shows the encapsulated coils and core.
  • Figure 7 discloses a magnetic component as a noise suppression filter.
  • the noise suppression filter comprises a flexible magnetic core 213 and two directly-fed-through coils, coil 210 and coil 21 1.
  • the coil 210 and the coil 211 can be two wires or two cables, and the flexible magnetic core is rolled around the two wires or two cables to form a closed loop magnetic core as showed in Figure 7.
  • the flexible magnetic core can be rolled for one layer, or can be rolled for a plurality of layers.
  • the coil 210 and the coil 21 1 can further be two lines of the power or signal circuits.
  • the coil 210 and the coil 211 can be the live line and neutral line of a power supply; for another example, the coil 210 and the coil 21 1 can be the positive power line and ground line respectively; and for another example, the coil 210 and the coil 21 1 can be two signal lines.
  • the wires for the coils and the flexible magnetic core can have the same characteristics as those illustrated in the common mode inductor in Figure 5.
  • An encapsulation casing can be included to secure the coil or coils and the flexible magnetic core.
  • Figure 8 discloses a magnetic component as another noise suppression filter.
  • the noise suppression filter comprises a flexible magnetic core 221 and a plurality of directly- fed-through coils 220.
  • the coils 220 can be a cable or a plurality of cables which can contain at least one conductive line, with the flexible magnetic core rolled around the directly-fed-through plurality of coils 220 to form a closed loop magnetic core.
  • the flexible magnetic core can be rolled for one layer, or can be rolled for a plurality of layers.
  • the plurality of coils 220 can contain a plurality of power lines and a plurality of signal lines.
  • the coils 220 can be a cable that contains at least the live and neutral line of a power supply; for another example, the coils 220 can be a cable that contains at least a positive power line and a ground line; for another example, the coils 220 can be a cable that contains a plurality of signal lines; and further for another example, the coils 220 can be a cable that contains a plurality of power lines and a plurality of signal lines.
  • the wires for the coils and the flexible magnetic core can have the same characteristics as those illustrated in the common mode inductor in Figure 5.
  • An encapsulation casing can be included to secure the coil or coils and the flexible magnetic core.
  • Figures 9 and 10 disclose a magnetic component as a radial inductor.
  • the radial inductor comprises a flexible magnetic core 303 and a coil 304.
  • the coil 304 further comprises a first end 300, a second end 301, and a single turn or a plurality of turns wrapped on the flexible magnetic core.
  • the materials for fabricating the coils can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bond able magnet wires, Litz. wire, and triple insulation wires.
  • the first end 300 and the second end 301 can be the same material as the coil 304 or different material, and can connect to the electrical circuit to receive and deliver current.
  • the flexible magnetic core comprises at least flexible magnetic sheet.
  • the magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials.
  • the magnetic sheet which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack.
  • the magnetic sheet further has a relatively high electrical resistivity.
  • the coil can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture.
  • the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed.
  • the coil can be wound on a fixture first and then be shifted onto the flexible magnetic core.
  • the combined object of the coil and the flexible magnetic core will be rolled together.
  • ways in rolling the wound flexible magnetic core which include but are not limited to the following three examples.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled magnetic core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized.
  • the core overlapping portion is directly contacted by the sheet material.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll through a small portion of a tape or a similar low magnetic conductive material to create a gap in the magnetic flux path.
  • the wound flexible magnetic core is rolled for a plurality of rolls.
  • Figuresl l -13 disclose a magnetic component as a low profile packed inductor.
  • the low profile packed inductor comprises a flexible magnetic core 403 and a coil 404.
  • the coil further comprises a first end 400, a second end 401 , and a single turn or a plurality of turns wrapped on the flexible magnetic core.
  • the materials for fabricating the coil can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, and triple insulation wires.
  • the first end 400 and the second end 401 can be the same material as the coil winding or different material, and can connect to the electrical circuit to receive and deliver electrical current.
  • the flexible magnetic core comprises at least one flexible magnetic sheet.
  • the magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials.
  • the magnetic sheet which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack.
  • the magnetic sheet further has a relatively high electrical resistivity.
  • the coil can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture.
  • the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed.
  • the coil can be wound on a fixture first and then be shifted onto the flexible magnetic core.
  • the combined object of the coil and the flexible magnetic core will be rolled together.
  • ways in rolling the wound flexible magnetic core which include but are not limited to the following three examples.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized.
  • the core overlapping portion is directly contacted by the sheet material.
  • the manufacturing process includes rolling the wound flexible magnetic core over one roll through a small portion of a tape or a similar low magnetic conductive material to create a gap in the magnetic flux path.
  • the wound flexible magnetic core is rolled for a plurality of rolls.
  • Figure 12 illustrates the finished encapsulated low profile packed inductor, and 405 in the figure 12 shows the encapsulated coil and core.
  • Figure 13 shows the surface mount option of this embodiment.
  • the first end of the coil 400 and the second end of the coil 401 are pressed to a flat shape and tinned. After the encapsulation, the flat and tinned first end of the coil 400 and the second end of the coil 401 are further bent to form surface mount pads.
  • 406 in figure 13 shows one surface mount pad of the low profile packed inductor and 407 in Figure 13 shows another surface mount pad of the low profile packed inductor.

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  • Microelectronics & Electronic Packaging (AREA)
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Abstract

A magnetic component structure is disclosed that includes at least one coil winding and at least one flexible magnetic core, made of a flexible magnetic sheet or sheets. The magnetic core with the wound coil or coils is configured to a rolled structure which forms a magnetic path. An encapsulation casing can be disposed around the rolled structure to secure the coil or coils and the flexible magnetic core. Also disclosed is a manufacturing process including both direct and indirect winding methods and rolling manufacturing steps. The rolling steps enable the magnetic component to form into a variety of shapes. A variety of magnetic components can be manufactured by using the magnetic component structure and the manufacturing method. Such magnetic components can be power management devices and electronic devices and they have high performance, small size and low electromagnetic emission.

Description

TITLE: MAGNETIC COMPONENTS AND ROLLING MANUFACTURING METHOD
This Patent Cooperation Treaty application is based upon and claims the filing date benefit of U.S. Provisional patent application (Application No. 61/837,207) filed on 6/20/2013.
Notice is hereby given that the following patent document contains original material which is subject to copyright protection. The copyright owner has no objection to the facsimile or digital download reproduction of all or part of the patent document, but otherwise reserves all copyrights whatsoever. BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention pertains to the design and manufacturing of electric or electronic devices and more particularly to the design and manufacturing of electric or electronic devices that include a magnetic component structure composed of at least one magnetic core to provide a magnetic path for the magnetic flux and at least one conductive coil winding to provide magneto-motive forces.
2. Description of the Related Art:
Developing modern electronic devices requires the magnetic components to be small in size, powerful in performance and minimal in electromagnetic interference. To decrease the overall structure size while enhancing electrical properties of such magnetic components, manufacturers must overcome many challenges that are associated with the complexity of manufacturing processes and the increase of manufacturing cost. The reduction of manufacturing cost has been strongly demanded for the small stnicture size yet powerful magnetic components such as inductors and transformers. This is so for those magnetic components of low cost and high volume.
The growing interest on the small size yet high power density electronic devices challenges the design and manufacturing of the magnetic components. The core size and the coil size must be reduced to reduce the overall structure size of the magnetic components despite an increased current being carried by the magnetic components. The manufacturing processes also need to be optimized and simplified to reduce the cost while improving the performance. Many efforts have been dedicated to optimize the core shapes to maximize the usage of the core material. Many efforts have also been contributed to simplify the manufacturing processes to reduce the manufacturing cost and improve the competitiveness.
Conventional magnetic components typically include a magnetic core and a winding or a coil wound on the magnetic core. The core may be fabricated from magnetic materials and is typically formed at certain shapes prior winding. The core may include over one core pieces and the shapes may include I core, EE core, U core, toroidal core, pot core, T core, and other shapes. The core may be bonded with epoxy, epoxy combined with glass bead, or other composite magnetic materials. The coils or windings are fabricated from a conductive wire such as a magnet wire or a tin coated copper wire. The coils are further fabricated by wrapping the wire around a core piece completely formed to a certain shape beforehand. SUMMARY OF THE INVENTION
This invention generally relates to the design and manufacturing of electric or electronic devices that include a magnetic component structure composed of at least one magnetic core to provide a magnetic path for the magnetic flux and at least one conductive coil winding to provide magneto-motive forces. Under the present invention, a conductive coil or coils are wound on a flexible magnetic core. A magnetic path is then formed by rolling the flexible magnetic core with the wound coil or coils to a closed or gapped loop which can be formed into variety of shapes such as a toroidal shape. The conductive coils can be made of including but not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, triple insulation wires, and cables. The coil or coils can be directly wound on the flexible magnetic core or indirectly wound on the flexible magnetic core with the use of a fixture. The fixture is used either together with or separately from the flexible magnetic core. When used together with the flexible magnetic core, the fixture guides the winding or windings on the flexible magnetic core. With the fixture and the flexible magnetic core separate, the indirect method winds the coil or coils on the fixture first and then shifts the coil or coils to the flexible magnetic core. The flexible magnetic core is made of a flexible magnetic sheet or sheets. The flexible magnetic sheet or sheets has or have predefined thickness, width, and length and has or have a relatively high electrical resistivity, and the flexible magnetic sheet or sheets can be but is not or are not limited to rectangular in shape. The magnetic sheet is fabricated by magnetic materials, such as magnetic powder materials or ferrite materials combined with flexible insulation materials, such as polymer or rubber. With the rolled structure of the magnetic sheet or sheets, a magnetic path is formed to facilitate the circulation of the magnetic flux. The rolling method enables the flexible magnetic core with the wound coil or coils to form different shapes. An encapsulation casing can be included to secure the coil winding or windings and the flexible magnetic core. The conductive coil or coils can include a plurality of turns. The conductive coil or coils can also be directly-fed-through wires, and the coils can be contained in a cable or a plurality of cables. A variety of magnetic components, including but not limited to axial inductors, radial inductors, common mode inductors, transformers, noise suppression filters, and low profile packed inductors can be manufactured by using the magnetic component structure and the manufacturing method. Such magnetic components may be power management devices in electrical systems and electronic devices in electronics, and such magnetic components have low electromagnetic emission and interference due to the looping nature of the magnetic flux path and in the meantime maintain high performance and small size due to the extensible nature of the flexible magnetic core. DESCRIPTION OF THE DRAWINGS
Figure 1 discloses a structure and a manufacturing step of winding a coil on a flexible magnetic core for one embodiment of the magnetic components as an axial inductor.
Figure 2 discloses a structure and a manufacturing step of rolling a wound core to form a looped magnetic flux path for one embodiment of the magnetic components as an axial inductor.
Figure 3 discloses a structure of a rolled assembly of a coil and a flexible magnetic core with a portion of the core overlapped and two end wires on the opposite sides for one embodiment of the magnetic components as an axial inductor.
Figure 4 discloses a completed assembly of coil, core and encapsulation casing for one embodiment of the magnetic components as an axial inductor.
Figures 5 discloses a structure of a rolled assembly of two coils and one flexible magnetic core with a portion of the core overlapped for another embodiment of the magnetic components as a common mode inductor.
Figures 6 discloses a completed assembly of coils and core for another embodiment of the magnetic components as a common mode inductor.
Figure 7 discloses a rolled assembly of one embodiment of the magnetic components as one noise suppression filter.
Figure 8 discloses a rolled assembly of one embodiment of the magnetic components as another noise suppression filter.
Figures 9 discloses a structure of a rolled assembly of a coil and a flexible magnetic core with a portion of the core overlapped and two end wires on the same side for another embodiment of the magnetic components as a radial inductor.
Figure 10 discloses a completed assembly of coil, core and encapsulation casing for one embodiment of the magnetic components as a radial inductor.
Figures 1 1 discloses a structure of a rolled assembly of a coil and a flexible magnetic core with a portion of the core overlapped and two end wires on the opposite sides for another embodiment of the magnetic components as a low profile packed inductor.
Figure 12 discloses an assembly of coil, core and encapsulation casing for one embodiment of the magnetic components as a low profile packed inductor.
Figure 13 shows a completed assembly of coil, core, encapsulation casing and surface mount options for one embodiment of the magnetic components as a low profile packed inductor. DESCRIPTION OF THE PREFERRED EMBODIMENTS ) This invention discloses the designs of magnetic components and the methods to manufacture such magnetic components. Preliminary experiment results confinn that higher performance and smaller footprint can be achieved by using these unique and simple designs and manufacturing methods than the traditional designs and manufacturing processes. AXIAL INDUCTORS
Figures 1-4 disclose a magnetic component as an axial power inductor. The axial power inductor comprises a ilexible magnetic core 102 and a coil 104. The coil 104 includes a first end 100, a second end 101, and a plurality of turns wrapped on the flexible magnetic core. The coil can be fabricated from materials that can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, and triple insulation wires. The first end 100 and the second end 101 can be the same material as the coil winding or different material. Both 100 and 101 can connect to the electrical circuit to receive and deliver electrical current. The flexible core comprises at least one flexible magnetic sheet. The magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials. The magnetic sheet, which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack. The magnetic sheet further has a relatively high electrical resistivity.
Figures 1 -4 also disclose the manufacturing process of this embodiment. First, wind a coil or winding on a flexible magnetic core composed of at least one flexible magnetic sheet. This step is illustrated in the Figure 1. The coil can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture. For example, the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed. For another example, the coil can be wound on a fixture first and then be shifted onto the flexible magnetic core. Second, roll the wound magnetic core to form a looped magnetic flux path. The combined object of the coil and the flexible magnetic core will be rolled together. There is a plurality of ways in rolling the wound flexible magnetic core, which include but are not limited to the following three examples. For the first example, which is illustrated in Figure 2 and Figure 3, the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled magnetic core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized. The core overlapping portion is directly contacted by the sheet material. For the second example, the manufacturing process includes rolling the wound flexible magnetic core over one roll through a small portion of a tape or a similar low magnetic conductive material to create a gap in the magnetic flux path. For the third example, the flexible magnetic core is rolled for a plurality of rolls. Third, secure and solidify the rolled coil and core by a piece of tape or by an epoxy resin encapsulation or by other means. Figure 4 illustrates the finished encapsulated axial power inductor. 105 in figure 4 shows the encapsulated coil and core, and the first end 100 and the second end 101 , which are on the opposite sides of the secure encapsulation, can be stripped and then tinned before or after these process steps. COMMON MODE INDUCTORS
Figures 5-6 disclose a magnetic component as a common mode inductor. The common mode inductor comprises a flexible magnetic core 206 and two coils, coil 204 and coil 205. The coil 204 further comprises a first end 202, a second end 203, and a single turn or a plurality of turns wrapped on the flexible magnetic core. The coil 205 further comprises a first end 200, a second end 201, and a single turn or a plurality of turns wrapped on the flexible magnetic core. The materials for fabricating the coils can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, and triple insulation wires. The first end 200 and the second end 201 of the coil 205 can be the same material as the coil 205 or different material, and can connect to the electrical circuit to receive and deliver current. The first end 202 and the second end 203 of the coil 204 can be the same material as the coil 204 or different material, and can connect to the electrical circuit to receive and deliver current. The flexible magnetic core comprises at least one flexible magnetic sheet. The magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials. The magnetic sheet, which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack. The magnetic sheet further has a relatively high electrical resistivity.
This embodiment can also be functioned as a transformer by configuring one coil as the electrical transformer primary winding and another coil as the electrical transformer secondary winding.
To manufacture this embodiment, first, wind two coils or windings on a flexible magnetic core composed of at least flexible magnetic sheet. The coils can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture. For example, the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed. For another example, the coils can be wound on a fixture first and then be shifted onto the flexible magnetic core. Second, roll the wound magnetic sheet core to form a looped magnetic flux path. The combined object of the coils and the flexible magnetic core will be rolled together. There is a plurality of ways in rolling the wound flexible magnetic core, which include but are not limited to the following two examples. For the first example, which is illustrated in Figure 5, the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized. The core overlapping portion is directly contacted by the sheet material. For the second example, the wound flexible magnetic core is rolled for a plurality of rolls. Third, secure and solidify the rolled coils and core by a piece of tape or by an epoxy resin encapsulation or by other means. Figure 6 illustrates the finished encapsulated common mode inductor, and component 207 in figure 6 shows the encapsulated coils and core. NOISE SUPPRESSION FILTERS
Figure 7 discloses a magnetic component as a noise suppression filter. The noise suppression filter comprises a flexible magnetic core 213 and two directly-fed-through coils, coil 210 and coil 21 1. The coil 210 and the coil 211 can be two wires or two cables, and the flexible magnetic core is rolled around the two wires or two cables to form a closed loop magnetic core as showed in Figure 7. The flexible magnetic core can be rolled for one layer, or can be rolled for a plurality of layers. The coil 210 and the coil 21 1 can further be two lines of the power or signal circuits. For one example, the coil 210 and the coil 211 can be the live line and neutral line of a power supply; for another example, the coil 210 and the coil 21 1 can be the positive power line and ground line respectively; and for another example, the coil 210 and the coil 21 1 can be two signal lines. The wires for the coils and the flexible magnetic core can have the same characteristics as those illustrated in the common mode inductor in Figure 5. An encapsulation casing can be included to secure the coil or coils and the flexible magnetic core.
Figure 8 discloses a magnetic component as another noise suppression filter. The noise suppression filter comprises a flexible magnetic core 221 and a plurality of directly- fed-through coils 220. The coils 220 can be a cable or a plurality of cables which can contain at least one conductive line, with the flexible magnetic core rolled around the directly-fed-through plurality of coils 220 to form a closed loop magnetic core. The flexible magnetic core can be rolled for one layer, or can be rolled for a plurality of layers. The plurality of coils 220 can contain a plurality of power lines and a plurality of signal lines. For one example, the coils 220 can be a cable that contains at least the live and neutral line of a power supply; for another example, the coils 220 can be a cable that contains at least a positive power line and a ground line; for another example, the coils 220 can be a cable that contains a plurality of signal lines; and further for another example, the coils 220 can be a cable that contains a plurality of power lines and a plurality of signal lines. The wires for the coils and the flexible magnetic core can have the same characteristics as those illustrated in the common mode inductor in Figure 5. An encapsulation casing can be included to secure the coil or coils and the flexible magnetic core.
RADIAL INDUCTORS
Figures 9 and 10 disclose a magnetic component as a radial inductor. The radial inductor comprises a flexible magnetic core 303 and a coil 304. The coil 304 further comprises a first end 300, a second end 301, and a single turn or a plurality of turns wrapped on the flexible magnetic core. The materials for fabricating the coils can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bond able magnet wires, Litz. wire, and triple insulation wires. The first end 300 and the second end 301 can be the same material as the coil 304 or different material, and can connect to the electrical circuit to receive and deliver current. The flexible magnetic core comprises at least flexible magnetic sheet. The magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials. The magnetic sheet, which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack. The magnetic sheet further has a relatively high electrical resistivity.
To manufacture this embodiment, first, wind a coil or winding on a flexible magnetic core composed of at least one flexible magnetic sheet. The coil can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture. For example, the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed. For another example, the coil can be wound on a fixture first and then be shifted onto the flexible magnetic core. Second, roll the wound magnetic core to form a looped magnetic flux path. The combined object of the coil and the flexible magnetic core will be rolled together. There is a plurality of ways in rolling the wound flexible magnetic core, which include but are not limited to the following three examples. For the first example, which is illustrated in Figure 9, the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled magnetic core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized. The core overlapping portion is directly contacted by the sheet material. For the second example, the manufacturing process includes rolling the wound flexible magnetic core over one roll through a small portion of a tape or a similar low magnetic conductive material to create a gap in the magnetic flux path. For the third example, the wound flexible magnetic core is rolled for a plurality of rolls. Third, secure and solidify the rolled coil and core by a piece of tape or by an epoxy resin encapsulation casing or by other means. 305 in figure 10 shows the encapsulated coil and core, and the first end 300 and the second end 301, which are on the same sides of the secure encapsulation casing, can be stripped and then tinned before or after these process steps. LOW PROFILE PACKED INDUCTORS
Figuresl l -13 disclose a magnetic component as a low profile packed inductor. The low profile packed inductor comprises a flexible magnetic core 403 and a coil 404. The coil further comprises a first end 400, a second end 401 , and a single turn or a plurality of turns wrapped on the flexible magnetic core. The materials for fabricating the coil can include but are not limited to insulated round magnet wires, insulated square or rectangular magnet wires, insulated square and rectangular conductive films, insulated bondable magnet wires, Litz wire, and triple insulation wires. The first end 400 and the second end 401 can be the same material as the coil winding or different material, and can connect to the electrical circuit to receive and deliver electrical current. The flexible magnetic core comprises at least one flexible magnetic sheet. The magnetic sheet can be a magnetic powder sheet fabricated from magnetic powder and polymeric resin, or a magnetic ferrite sheet fabricated from Ferrite and polymeric resin, or any magnetic material sheet fabricated from magnetic property materials and flexible resin materials or rubber materials. The magnetic sheet, which has a predefined thickness, width, length and relative magnetic permeability, is flexible and can roll at a small radius without crack. The magnetic sheet further has a relatively high electrical resistivity.
To manufacture this embodiment, first, wind a coil or winding on a flexible magnetic core composed of at least one flexible magnetic sheet. The coil can be directly wound on the flexible magnetic core or can be indirectly wound on the flexible magnetic core with the use of a fixture. For example, the coil can be wound on the combined object of the flexible magnetic core and the fixture with the fixture removed after the winding is completed. For another example, the coil can be wound on a fixture first and then be shifted onto the flexible magnetic core. Second, roll the wound magnetic core to form a square-loop or a rectangle-loop magnetic flux path. The combined object of the coil and the flexible magnetic core will be rolled together. There is a plurality of ways in rolling the wound flexible magnetic core, which include but are not limited to the following three examples. For the first example, which is illustrated in Figure 11 , the manufacturing process includes rolling the wound flexible magnetic core over one roll, and there is a small portion of the rolled core overlapped so the magnetic flux path is a closed loop and the magnetic flux will circulate inside the core. By doing so, the magnetic flux that escapes to the adjacent area can be minimized and the electromagnetic emission can be minimized. The core overlapping portion is directly contacted by the sheet material. For the second example, the manufacturing process includes rolling the wound flexible magnetic core over one roll through a small portion of a tape or a similar low magnetic conductive material to create a gap in the magnetic flux path. For the third example, the wound flexible magnetic core is rolled for a plurality of rolls. Third, secure and solidify the rolled coil and core by a piece of tape or by an epoxy resin encapsulation casing or by other means. Figure 12 illustrates the finished encapsulated low profile packed inductor, and 405 in the figure 12 shows the encapsulated coil and core.
Figure 13 shows the surface mount option of this embodiment. According to this embodiment option, the first end of the coil 400 and the second end of the coil 401 are pressed to a flat shape and tinned. After the encapsulation, the flat and tinned first end of the coil 400 and the second end of the coil 401 are further bent to form surface mount pads. 406 in figure 13 shows one surface mount pad of the low profile packed inductor and 407 in Figure 13 shows another surface mount pad of the low profile packed inductor.
In compliance with the statute, the invention described has been described in language more or less specific as to structural features. It should be understood however, that the invention is not limited to the specific features shown, since the means and construction shown, comprises the preferred embodiments for putting the invention into effect. The invention is therefore claimed in its forms or modifications within the legitimate and valid scope of the amended claims, appropriately interpreted under the doctrine of equivalents.

Claims

CLAIMS I claim:
1. A magnetic component, comprising:
a. at least one coil winding and at least one flexible magnetic core;
b. at least one coil winding wound around said magnetic core,
c. said magnetic core made of at least one flexible magnetic sheet,
d. said magnetic core and said coil winding being configured into a partially or completely rolled structure thereby forming a looped magnetic flux path.
2. The magnetic component, as recited in Claim 1 , further including an encapsulation casing disposed around said rolled structure.
3. The magnetic component, as recited in Claim 1 , further including the magnetic flux path formed into toroidal, oval, square, rectangular and any other shapes.
4. The magnetic component, as recited in Claim 1, further including the rolled structure having a small portion of the rolled core overlapped.
5. The magnetic component, as recited in Claim 1 , further including:
a. said rolled structure having a gap in the magnetic flux path,
b. said gap being a small portion of tape, a similar low magnetic conductive material or any other material.
6. The magnetic component, as recited in Claim 1, further including the rolled structure having a plurality of rolls.
7. The magnetic component, as recited in Claim 1, further including:
a. one coil winding and one magnetic core,
b. said magnetic component having first end and second end on the opposite sides, c. said magnetic component being said an axial inductor.
8. The magnetic component, as recited in Claim 1 , further including:
a. one coil winding and one magnetic core,
b. said magnetic component having first end and second end on the same side, c. said magnetic component being said a radial inductor.
9. The magnetic component, as recited in Claim 1, further including:
a. two coil windings and one magnetic core,
b. said magnetic component being said a common mode inductor or a transformer.
10. The magnetic component, as recited in Claim 1 , further including:
a. one coil winding and one magnetic core,
b. said rolled structure having a quasi- rectangular shape, quasi-square shape or other shapes,
c. said magnetic component having first end and second end
d. said magnetic component being said a low profile inductor.
1 1. The magnetic component as claimed in claim 10, wherein the first end and the second end of the coil are further pressed to a flat shape and tinned, and the first end and the second end are then bent to form the surface mount pads after the coil and the core are encapsulated.
12. A magnetic component manufacturing process, including:
a. forming flexible magnetic core of a rectangular-like shape with an X- direction and a Y-direction;
b. said flexible magnetic core made of at least one flexible magnetic sheet, c. winding at least one coil on said flexible magnetic core in the Y-direction of the rectangular-like shape directly or indirectly; d. rolling the wound structure in the X-direction of the rectangular-like shape to form a magnetic flux path;
e. said direct method including winding the coil directly on the core, f. said indirect method including the usage of a fixture,
g. said usage of fixture including the fixture used together with the core or the fixture used separately to wind the coil,
h. said fixture used together with the core including removing the fixture after the winding is completed,
i. said fixture used separately including shifting the wound coil to the core.
13. A magnetic component that comprises one coil or a plurality of coils and a flexible magnetic core, and the coils can be directly-fed-through wires, a cable or a plurality of cables, and the flexible magnetic core is composed of a flexible magnetic sheet or sheets, and the manufacturing process includes rolling the magnetic sheet or sheets around the coils or the cable or a plurality of cables to form a magnetic flux path, and an encapsulation casing can be included to secure the coil or coils and the flexible magnetic core, and this magnetic component is said a noise suppression filter.
14. The magnetic component structure as claimed in Claim 1 , and Claim 13, wherein the flexible magnetic sheet or sheets used to make the flexible magnetic core has or have predefined thickness, width, length and relative magnetic permeability and has or have a relatively high electrical resistivity, and the flexible magnetic sheet or sheets can be but is not or are not limited to rectangular in shape.
15. The magnetic component structure as claimed in Claim 1 , and Claim 13, wherein the flexible magnetic sheet or magnetic sheets is or are composed of magnetic materials and insulation materials, and the magnetic materials include but are not limited to magnetic powder materials, magnetic ferrite materials, and any magnetic property materials and the insulation materials include but are not limited to flexible polymeric resin materials and rubber materials.
PCT/US2014/043093 2013-06-20 2014-06-19 Magnetic components and rolling manufacturing method WO2014205164A1 (en)

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