A mother substrate that enables winding cores to be obtained in a manner in which the mother substrate is divided along x-direction division lines and y-direction division lines is prepared. Subsequently, x-direction division grooves are formed along the x-direction division lines on a first main surface of the mother substrate, y-direction division grooves are formed along the y-direction division lines on the first main surface, and shallow bottom surface exposure grooves, for exposing surfaces that are to be core portion bottom surfaces, are formed on the first main surface. The mother substrate is divided by performing a flattening process on a second main surface of the mother substrate that is opposite the first main surface until the second main surface reaches the x-direction division grooves and the y-direction division grooves to obtain the winding cores that are separated from each other.

A magnetic assembly includes a magnetic core, four primary windings and four secondary windings. The magnetic core includes four lateral legs. The four primary windings and the corresponding secondary windings are magnetically coupled with each other, and the four primary windings and the corresponding secondary windings are wound on the corresponding lateral legs. The winding directions of the four secondary windings on the corresponding lateral legs are identical. A phase difference between a magnetic flux flowing through a specified lateral leg of the four lateral legs and a magnetic flux flowing through an adjacent lateral leg is any value in the range between 150 degrees and 210 degrees. A phase difference between the magnetic flux flowing through the specified lateral leg and the magnetic flux flowing through another adjacent lateral leg is any value in the range between 60 degrees and 120 degrees.

The present disclosure is related to a power module power structure and an assembling method thereof. The power module structure includes a first printed-circuit-board (PCB) assembly, a second PCB assembly, and a conductive connection component. The first PCB assembly includes a first circuit board, a power switch and a magnetic component. The first circuit board includes a first side, a second side and a through hole. The power switch is disposed on the first circuit board. The magnetic component includes a first magnetic core and a second magnetic core fastened on the first circuit board through the through hole. The second PCB assembly includes a second circuit board having a third side, a fourth side and a hollow slot passing therethrough. The second magnetic core is exposed through the hollow slot. The conductive connection component is disposed and electrically connected between the first PCB assembly and the second PCB assembly.

The present disclosure is related to a power module includes a first printed circuit board (PCB), a second PCB, a magnetic component and a connecting component. A secondary side switch set and a winding are disposed on the first PCB, respectively. A primary side switch set is disposed on the second PCB adjacent to the first PCB. A magnetic component includes an upper magnetic cover disposed on the first side of the first PCB; a lower magnetic cover disposed between the first PCB and the second PCB; and a lateral column located between the two magnetic covers. The lateral column passes through the first PCB, and is fastened with the two magnetic covers. The magnetic component and the winding collaboratively form a transformer. The connecting component is disposed between the two PCBs to connect the corresponding potential points of the two PCBs.

The first core includes a main body part extending in a first direction along a main surface of the substrate, a first foot part extending from the main body part to the second core through the substrate, and a second foot part extending from the main body part to the second core through the substrate at a position at which the coil conductor is sandwiched between itself and the first foot part in the first direction, and the insulating member includes a bottom wall part interposed between at least the first foot part and the second core, and a side wall part extending along at least either of the first foot part and the second foot part and interposed between either of the foot parts and the coil conductor.

A reactor including a magnetic core and a coil having a wound part, the magnetic core having an inner core part disposed inside the wound part and an outer core part disposed outside the wound part, is provided with a bolt coupling the inner core part and the outer core part, the bolt being constituted by a composite material formed by dispersing a soft magnetic powder in a resin and including a shaft part passing through the outer core part, the shaft part including a tip reaching the inner core part, and the inner core part and the outer core part respectively being an integrated member having an undivided structure.

Embodiments of the disclosure relate to apparatuses for enhanced thermal management of a planar inductor assembly. In one embodiment, a cooling package for an inductor assembly includes a cold plate and a heat-spreading bracket mechanically coupled to the cold plate at a first end of the heat-spreading bracket. The cold plate has a slotted recess for mounting a first inductor core along a first end thereof. The heat-spreading bracket is configured to apply a clamping force to a second inductor core at a second end opposite to the first end of the heat-spreading bracket.

An inductor is provided, comprising: a first ferrite core piece and a second ferrite core piece, each of which are made of substantially similar materials, exhibit desired electromagnetic properties, and which are fashioned in a substantially similar manner and shape, and wherein each of the first and second ferrite core pieces comprises a substantially planar mating surface, a center post, and a wire core assembly channel, and wherein a first substantially planar mating surface of the first ferrite core piece is adapted to planarly mate with a second substantially planar mating surface of the second ferrite core piece; and a wire core assembly adapted to be substantially self-locating and self-centering about a first or second center post when located in a respective first or second wire core assembly channel.

A battery pack charging system includes a battery pack interface configured to receive a battery pack, a charging circuit coupled to the battery pack interface to provide charging current to the battery pack interface, and a controller coupled to the charging circuit and configured to control supply of charge current to the battery interface. The battery pack charging system further includes a power supply circuit coupled to the charging circuit, a filter circuit coupled to the power supply circuit and including a nanocrystalline ferrite common mode choke, and an alternating current plug configured to connect the filter circuit to an alternating current power source.

A power converter includes a circuit board, a first magnetic core, and a housing. The circuit board includes an insulating substrate and a first coil conductor. The insulating substrate includes a first side surface. The first magnetic core includes a first magnetic core member and a second magnetic core member. A first side surface of the insulating substrate is opposed to a first portion of the housing and is spaced away from the first portion of the housing. The first magnetic core member and the second magnetic core member are both thermally connected to the first portion.