Packaging structure of a magnetic device

Abstract

A magnetic device comprising a T-shaped magnetic core made of a material comprising a soft magnetic metal material and having a base and a pillar integrally formed with the base; a coil wound on the pillar; and a unitary magnetic body encapsulating the pillar, the coil and a portion of the base with a bottom surface of the base being not covered by the unitary magnetic body, wherein a contiguous portion of the unitary magnetic body encapsulates a top surface of the pillar and extends into a gap between a side surface of the pillar and an inner surface of the coil, wherein the core loss P.sub.BL (mW/cm.sup.3) of the unitary magnetic body satisfies: 2f.sup.1.29Bm.sup.2.2P.sub.BL14.03f.sup.1.29B.sub.m.sup.1.08, where f(kHz) represents a frequency of a magnetic field applied to the T-shaped magnetic core, and B.sub.m (kGauss) represents the operating magnetic flux density of the magnetic field at the frequency.

Claims

1. A magnetic device, comprising: a T-shaped magnetic core, comprising a base and a pillar integrally formed with the base, the base having a top side and a bottom side opposite to the top side, the pillar being located on the top side of the base; a coil wound on the pillar; and a unitary magnetic body, encapsulating the pillar, the coil and a portion of the base with a bottom surface of the base being not covered by the unitary magnetic body, wherein a contiguous portion of the unitary magnetic body being made of a same material is disposed across and encapsulates a top surface of the pillar and a top surface of the coil and extends into a gap between a side surface of the pillar and an inner surface of the coil with a bottom surface of said contiguous portion being in contact with a top surface of the base, wherein an equivalent permeability of the magnetic device is between 28.511 and 52.949, wherein the core loss PBL (mW/cm3) of the unitary magnetic body satisfies: 2f1.29Bm2.2PBL14.03f1.29Bm1.08, where f(kHz) represents a frequency of a magnetic field applied to the T-shaped magnetic core, and Bm (kGauss) represents the operating magnetic flux density of the magnetic field at the frequency.

2. The magnetic device of claim 1, wherein the core loss PCL (mW/cm3) of the T-shaped magnetic core satisfies: 0.64f1.15Bm2.20PCL4.79f1.41Bm1.08.

3. The magnetic device of claim 1, wherein the magnetic device is an inductor, wherein a volume V1 of the base and a volume V2 of the pillar satisfies: V1/V25.065, and the total core loss of the inductor is not greater than 760.52 mW.

4. The magnetic device of claim 1, wherein the magnetic device is an inductor, wherein a volume V1 of the base and a volume V2 of the pillar satisfies: V1/V22.093, and the total core loss of the inductor is not greater than 483.24 mW.

5. The magnetic device of claim 1, wherein the T-shaped magnetic core comprises a soft magnetic metal material comprising FeSi alloy powder, wherein the permeability of the T-shaped magnetic core is between 48 and 108.

6. The magnetic device of claim 1, wherein the T-shaped magnetic core comprises a soft magnetic metal material comprising FeSiAl alloy powder, wherein the permeability of the T-shaped magnetic core is between 48 and 150.

7. The magnetic device of claim 1, wherein the T-shaped magnetic core comprises a soft magnetic metal material comprising FeNi alloy powder, wherein the permeability of the T-shaped magnetic core is between 48 and 192.

8. The magnetic device of claim 1, wherein the T-shaped magnetic core comprises a soft magnetic metal material comprising FeNiMo alloy powder, wherein the permeability of the T-shaped magnetic core is between 48 and 240.

9. The magnetic device of claim 1, wherein the coil is a pre-wound hollow coil having two integral leads for connecting with an external circuit.

10. The magnetic device of claim 1, wherein the magnetic device is an inductor.

11. The magnetic device of claim 1, wherein the magnetic device is a choke.

12. The magnetic device of claim 1, wherein two electrodes are embedded in the base, said two electrodes being electrically connected to two leads of the coil, wherein the base has two recesses respectively located on two lateral sides of the base, the two recesses respectively receiving said two leads of the coil so that the two leads are respectively in contact with the two electrodes via the two recesses.

13. A magnetic device, comprising: a T-shaped magnetic core, comprising a base and a pillar integrally formed with the base, the base having a top side and a bottom side opposite to the top side, the pillar being located on the top side of the base; a coil wound on the pillar; and a unitary magnetic body, encapsulating the pillar, the coil and a portion of the base with a bottom surface of the base being not covered by the unitary magnetic body, wherein a contiguous portion of the unitary magnetic body being made of a same material is disposed across and encapsulates a top surface of the pillar and a top surface of the coil and extends into a gap between a side surface of the pillar and an inner surface of the coil with a bottom surface of said contiguous portion being in contact with a top surface of the base, wherein an equivalent permeability of the magnetic device is between 28.511 and 52.949.

14. The magnetic device of claim 13, wherein the magnetic device is an inductor, wherein a volume V1 of the base and a volume V2 of the pillar satisfies: V1/V25.065, and the total core loss of the inductor is not greater than 760.52 mW.

15. The magnetic device of claim 13, wherein the magnetic device is an inductor, wherein a volume V1 of the base and a volume V2 of the pillar satisfies: V1/V22.093, and the total core loss of the inductor is not greater than 483.24 mW.

16. The magnetic device of claim 13, wherein the magnetic device is an inductor.

17. The magnetic device of claim 13, wherein the magnetic device is a choke.

18. The magnetic device of claim 13, wherein the core loss PBL (mW/cm.sup.3) of the unitary magnetic body satisfies: 2f1.29Bm2.2PBL14.03f1.29Bm1.08, where f(kHz) represents a frequency of a magnetic field applied to the T-shaped magnetic core, and Bm (kGauss) represents the operating magnetic flux density of the magnetic field at the frequency.

19. The magnetic device of claim 13, wherein BHsat2250, where B is a permeability of the unitary magnetic body, and Hsat (Oe) is a strength of the magnetic field at 80% of B0, where B0 is the permeability of the unitary magnetic body when the strength of the magnetic field is 0.

20. A magnetic device, comprising: a T-shaped magnetic core, comprising a base and a pillar integrally formed with the base, the base having a top side and a bottom side opposite to the top side, the pillar being located on the top side of the base; a coil wound on the pillar; and a unitary magnetic body, encapsulating the pillar, the coil and a portion of the base with a bottom surface of the base being not covered by the unitary magnetic body, wherein a contiguous portion of the unitary magnetic body being made of a same material is disposed across and encapsulates a top surface of the pillar and a top surface of the coil and extends into a gap between a side surface of the pillar and an inner surface of the coil with a bottom surface of said contiguous portion being in contact a top surface of the base, wherein an equivalent permeability of the magnetic device is between 28.511 and 52.949, wherein BHsat2250, where B is a permeability of the unitary magnetic body, and Hsat (Oe) is a strength of the magnetic field at 80% of B0, where B0 is the permeability of the unitary magnetic body when the strength of the magnetic field is 0.

21. The magnetic device of claim 20, wherein the magnetic device is an inductor, wherein a volume V1 of the base and a volume V2 of the pillar satisfies: V1/V25.065, and the total core loss of the inductor is not greater than 760.52 mW.

22. The magnetic device of claim 20, wherein the magnetic device is an inductor, wherein a volume V1 of the base and a volume V2 of the pillar satisfies: V1/V22.093, and the total core loss of the inductor is not greater than 483.24 mW.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:

(2) FIGS. 1A-1C illustrate three types of conventional chokes;

(3) FIGS. 2A-2G illustrate a perspective view of a T-shaped magnetic core, a wire coil, and a choke in accordance with various embodiments of the present invention;

(4) FIG. 3A is a cross-sectional view of a choke in accordance with an embodiment of the present invention;

(5) FIG. 3B is a perspective view of a T-shaped magnetic core in accordance with another embodiment of the present invention;

(6) FIG. 3C is a cross-sectional view of a choke with the T-shaped magnetic core as shown in FIG. 3B in accordance with an embodiment of the present invention;

(7) FIG. 3D is a cross-sectional view of a choke in accordance with still another embodiment of the present invention;

(8) FIG. 4A is a top view of a T-shaped magnetic core in accordance with an embodiment of the present invention;

(9) FIG. 4B is a top view of a T-shaped magnetic core in accordance with another embodiment of the present invention;

(10) FIGS. 5A and 5B are lateral views and top views of T-shaped magnetic cores in accordance with two embodiments of the present invention;

(11) FIG. 6 illustrates curves showing the upper limit and the lower limit of the permeability of the T-shaped core and the permeability of the magnetic body and the relationship between the permeability of the T-shaped core and the permeability of the magnetic body in accordance with an embodiment of the present invention; and

(12) FIG. 7 illustrates the efficiency comparison between a choke in accordance with an embodiment of the present invention and a conventional choke with a toroidal core.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

(13) The present invention will now be described in detail with reference to the accompanying drawings, wherein the same reference numerals will be used to identify the same or similar elements throughout the several views. It should be noted that the drawings should be viewed in the direction of orientation of the reference numerals.

(14) FIGS. 2A-2C is a perspective view of a choke in accordance with an embodiment of the present invention. As embodied in FIGS. 2A-2C, the choke 1 as a magnetic device comprises a T-shaped magnetic core 2, a wire coil 3 and a magnetic body 4. The T-shaped magnetic core 2 includes a base 21 and a pillar 22. The base 21 has a first/top surface and a second/bottom surface opposite to the first/top surface. The pillar 22 is located on the first/top surface of the base 21. The second/bottom surface of the base 21 is exposed to the outer environment as an outer surface of the choke 1. The wire coil 3 forms a hollow part for accommodating the pillar 22 such that the wire coil 3 surrounds the pillar 22. In one embodiment of the present invention, as shown in FIG. 2C, the wire has two leads 31, 32 as welding pins without the need of using electrodes on the base 21. In another embodiment of the present invention, as shown in FIG. 3D, the wire has two leads 31, 32 respectively connected to two electrodes 5 and 6 on the base 21. The magnetic body 4 fully covers the pillar 22, any part of the base 21 that is located above the second/bottom surface of the base 21, and any part of the wire coil 3 that is located above the first/top surface of the base 21.

(15) In an embodiment of the present invention, the T-shaped magnetic core 2 is made of an annealed soft magnetic metal material. In particular, a soft magnetic metal material selected from the group consisting of FeSi alloy powder, FeSiAl alloy powder, FeNi alloy powder, FeNiMo alloy powder, and a combination of two or more thereof is first pressed to form the T-shaped structure (i.e., base+pillar) of the T-shaped magnetic core 2. After the T-shaped structure is formed, an annealing process is performed on the T-shaped structure to obtain the annealed T-shaped magnetic core 2 with low core loss.

(16) A relationship can be used describe the core losses of the magnetic material. This relationship takes the following form:
PL=CfaBmb,

(17) In this relationship, PL is the core loss per unit volume (mW/cm3), f (kHz) represents a frequency of a magnetic field applied to the magnetic material, and Bm (kGauss, and is usually less than one (1)) represents the operating magnetic flux density of the magnetic field at the frequency. In addition, the coefficients C, a and b are based on factors such as the permeability of the magnetic materials.

(18) TABLES 1-4 illustrate the coefficients C, a and b when different soft magnetic metal materials with different permeabilities are used to form the annealed T-shaped magnetic core 2.

(19) TABLE-US-00001 TABLE 1 FeNiMo alloy powder (MPP) Permeability .sub.CC C a b 14 2.33 1.31 2.19 26 1.39 1.28 1.29 60 0.64 1.41 2.20 125 1.02 1.40 2.03 147 1.08 1.40 2.04 160 1.08 1.40 2.04 173, 200 1.08 1.40 2.04

(20) TABLE-US-00002 TABLE 2 FeNi alloy powder (High Flux) Permeability .sub.CC C a b 14 7.26 0.95 1.91 26 3.19 1.22 1.08 60 3.65 1.15 2.16 125 1.62 1.32 2.20 147 1.74 1.32 2.10 160 1.74 1.32 2.10

(21) TABLE-US-00003 TABLE 3 FeSiAl alloy powder (Sendust) Permeability .sub.CC C a b 14 3.18 1.21 2.09 26 2.27 1.26 2.08 60, 75, 90, 125 2.00 1.31 2.16

(22) TABLE-US-00004 TABLE 4 FeSi alloy powder (Power Flux) Permeability .sub.CC C a b 60, 90 4.79 1.25 2.05

(23) In view of the above, in accordance with some embodiments of the present invention, the core loss PCL (mW/cm3) of the annealed T-shaped magnetic core 2 satisfies:
0.64f0.95Bm2.20PCL7.26f1.41Bm1.08.

(24) In some embodiments of the present invention, the permeability C of the annealed T-shaped magnetic core 2 has the average permeability CC with 20% deviation, and the average permeability CC is equal or larger than 60. For example, the annealed T-shaped magnetic core 2 is an annealed T-shaped structure made from soft magnetic metal material such as FeSi alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 90 (i.e., permeability C is between 48 (i.e., 80% of 60) and 108 (120% of 90)), FeSiAl alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 125 (i.e., permeability C is between 48 (i.e., 80% of 60) and 150 (120% of 125)), FeNi alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 160 (i.e., permeability C is between 48 (i.e., 80% of 60) and 192 (120% of 160)), or FeNiMo alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 200 (i.e., permeability C is between 48 (i.e., 80% of 60) and 240 (120% of 200)), and the core loss PCL (mW/cm3) of the annealed T-shaped magnetic core 2 satisfies:
0.64f1.15Bm2.20PCL4.79f1.41Bm1.08.

(25) In some embodiments of the present invention, the annealed T-shaped magnetic core 2 is an annealed T-shaped structure made from soft magnetic metal material such as FeSiAl alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 125 (i.e., permeability C is between 48 (i.e., 80% of 60) and 150 (120% of 125)), FeNi alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 160 (i.e., permeability C is between 48 (i.e., 80% of 60) and 192 (120% of 160)), or FeNiMo alloy powder with the average permeability CC of the annealed T-shaped magnetic core 2 between 60 and 200 (i.e., 80% of 60) and 240 (120% of 200)), and the core loss PCL (mW/cm3) of the annealed T-shaped magnetic core 2 satisfies:
0.64f1.31Bm2.20PCL2.0f1.41Bm1.08

(26) In addition, the value of CCHsat is a major bottleneck for the current tolerance of a choke, where Hsat (Oe) is a strength of the magnetic field at 80% of C0, and C0 is the permeability of the T-shaped magnetic core 2 when the strength of the magnetic field is 0. TABLE 5 illustrates the value of CCHsat when different annealed soft magnetic metal materials with different permeabilities are used to form the annealed T-shaped magnetic core 2.

(27) TABLE-US-00005 TABLE 5 FeSi alloy Core powder Material FeSiAl alloy powder (Sendust) (Power Flux) .sub.CC 60 75 90 125 60 90 Hsat (Oe) 42 32 29 18 70 48 .sub.CC Hsat 2520 2400 2610 2250 4200 4320 Core Material FeNiMo alloy powder (MPP) .sub.CC 60 125 147 160 173 200 Hsat (Oe) 60 30 28 23 21 16 .sub.CC Hsat 3600 3750 4116 3680 3633 3200 Core FeNi alloy Material powder (High Flux) .sub.CC 60 125 147 160 Hsat (Oe) 105 42 39 32 .sub.CC Hsat 6300 5250 5733 5120

(28) In view of the above, in accordance with the embodiments of the present invention, the following requirement is also satisfied:
CCHsat2250

(29) In an embodiment of the present invention, the two electrodes 5, 6 are located at the bottom of the base 21, as shown in FIG. 3A. In another embodiment of the present invention, the two electrodes 5, 6 are embedded in the base 21, as shown in FIGS. 3B, 3C and 3D. As shown in FIG. 3B, the bottom surface of each of the two electrodes 5, 6 is substantially coplanar with the second/bottom surface of the base 21, and a lateral surface of each of the two electrodes 5, 6 is substantially coplanar with a corresponding one of two opposite lateral surfaces of the base 21. The embedded electrodes provide the features that more magnetic materials can occupy the annealed T-shaped magnetic core 2 when the dimension of the annealed T-shaped magnetic core 2 is fixed, which enhance the effective permeability of the annealed T-shaped magnetic core 2.

(30) In another embodiment of the present invention, as shown in FIGS. 2A and 3D, the base 21 has two recesses 211, 212 respectively located on two lateral sides of the base 21, and the two recesses 211, 212 respectively receive the two leads 31, 32 of the wire coil 3. In the embodiment as shown in FIGS. 2A-2C, the two leads 31, 32 pass through the base 21 via the two recesses 211, 212 without electrodes on the base 21. In the embodiment as shown in FIG. 3D, the two leads 31, 32 are respectively in contact with the two electrodes 5, 6 via the two recesses 211, 212. In another embodiment of the present invention, as shown in FIG. 2D, the base 21 does not have the recesses for receiving the two leads 31, 32; instead, the two leads 31, 32 extend through the magnetic body 4 at the lateral side of the choke 1 without passing through the base 21. In still other embodiments of the present invention, as shown in FIGS. 2E and 2F, the base 21 has two recesses on the same lateral side for receiving the two leads 31, 32. In still another embodiment of the present invention, as shown in FIG. 2G the base 21 does not have the recesses for receiving the two leads 31, 32; instead, the two leads 31, 32 are fully located above the base 21, and are in contact with the two electrodes 5, 6 on the top surface of the base 21. The two electrodes 5, 6 in the embodiment shown in FIG. 2G extend from the bottom surface of the base 21 to the top surface of the base 21. In the embodiments shown in FIGS. 2A-2G the magnetic body 4 fully covers the pillar 22, and any part of the base 21 that is located above the second/bottom surface of the base 21.

(31) In an embodiment of the present invention, the base 21 is a rectangular (including a square) base with four right-angled corners or four curved corners (see FIGS. 5A and 5B), and a shortest distance (a, b, c, d as shown in FIGS. 4A and 4B) from each of the four ends of the rectangular base 21 to the pillar 22 is substantially the same (i.e., a=b=c=d). As a result, the magnetic circuit of the T-shaped magnetic core 2 is uniform and the core loss of the T-shaped magnetic core 2 can be minimized. It should be noted that FIGS. 4A and 4B simply illustrate the embodiments of the rectangular base 21 with four right-angled corners; however, the same features (i.e., a shortest distance (a, b, c, d) from each of the four ends of the rectangular base 21 to the pillar 22 is substantially the same (i.e., a=b=c=d)) also applied to the embodiments of the rectangular base 21 with four curved corners as shown in FIG. 5B.

(32) In an embodiment of the present invention, the magnetic body 4 is made by mixing a thermal setting material (such as resin) and a material selected from the group consisting of iron-based amorphous powder, FeSiAl alloy powder, permally powder, ferro-Si alloy powder, nanocrystalline alloy powder, and a combination of two or more thereof, and the mixture is then hot-pressed into a thermal setting mold where the T-shaped magnetic core 2 with the wire coil 3 thereon is located. Therefore, the hot-pressed mixture (i.e., the magnetic body 4) fully covers the pillar 22, any part of the base 21 that is located above the second/bottom surface of the base 21, and any part of the wire coil 3 that is located above the first/top surface of the base 21 as shown in FIGS. 2C and 2E-2G. In the embodiment as shown in FIG. 2D, the hot-pressed mixture (i.e., the magnetic body 4) fully covers the pillar 22, any part of the base 21 that is located above the second/bottom surface of the base 21, and any part of the wire coil 3 that is located directly above the first/top surface of the base 21, but does not cover a part of the wire coil 3 that is not located directly above the first/top surface of the base 21 (e.g., the two leads that are not located directly above the first/top surface of the base 21).

(33) In an embodiment of the present invention, the permeability B of the magnetic body has 20% deviation from an average permeability BC of the magnetic body 4, the average permeability BC is equal to or larger than 6, and the core loss PBL (mW/cm3) of the magnetic body 4 satisfies:
2f1.29Bm2.2PBL14.03f1.29Bm1.08

(34) In another embodiment of the present invention, the permeability B of the magnetic body 4 satisfies: 9.85B64.74, and the core loss PBL (mW/cm3) of the magnetic body further satisfies:
2f1.29Bm2.2PBL11.23f1.29Bm1.08

(35) In another embodiment of the present invention, the permeability B of the magnetic body 4 satisfies: 20B40, and the core loss PBL (mW/cm3) of the magnetic body further satisfies:
2f1.29Bm2.2PBL3.74f1.29Bm1.08

(36) In addition, in an embodiment of the present invention, the following requirement is also satisfied:
BCHsat2250,

(37) where Hsat (Oe) is a strength of the magnetic field at 80% of B0, where B0 is the permeability of the magnetic body 4 when the strength of the magnetic field is 0.

(38) In addition, the dimension of the T-shaped magnetic core 2 will also affect the core loss of the choke. TABLE 6 shows the total core loss of the chokes with different dimensions of the T-shaped magnetic cores, where C is the diameter of the pillar 22, D is the height of the pillar 22, E is the thickness of the base 21, and the T-shaped magnetic cores in TABLE 6 have the same height B (6 mm) and same width A (14.1 mm), as shown in FIG. 5A. In addition, V1 is the volume of the base 21, V2 is the volume of the pillar 22, Vc is the volume of the T-shaped magnetic core 2 (i.e., V1+V2), and V is the volume of the thermal setting mold/choke 1. As shown in FIGS. 5A and 5B, the base of the T-shaped magnetic core 2 is a rectangular base with four right-angled corners or four curved corners.

(39) In the examples of TABLE 6, the T-shaped magnetic core 2 is made of an annealed FeSiAl alloy powder with the permeability of about 60 (Sendust 60), and the magnetic body 4 is made of a hot-pressed mixture of resin and iron-based amorphous powder and has a permeability of about 27.5. In addition, the size of the thermal setting mold (and therefore the size of the choke 1) V is 14.514.57.0=1471.75 mm3.

(40) TABLE-US-00006 TABLE 6 Size Core Material: Sendust 60 14.5 14.5 7.0 Hot-Pressed Mixture: = 27.5 Core Core Loss C D E Bm P.sub.CV Volume CoreLoss Total Core NO. (mm) (mm) (mm) V1/V2 Part (mT) (kW/m.sup.3) (mm.sup.3) (mW) Loss (mW) V.sub.C/V 1 5.5 5.2 0.8 1.288 T-shaped 59.99 689.01 282.6 194.71 362.97 19.2% Magnetic Core Magnetic 14.79 209.31 803.9 168.26 Body 2 5.0 4.0 2.0 5.065 T-shaped 76.72 1169.26 476.2 556.80 760.52 32.26% Magnetic Core Magnetic 17.14 291.69 698.4 203.72 Body 3 5.0 4.8 1.2 2.533 T-shaped 78.9 1241.86 332.8 413.29 695.02 22.62% Magnetic Core Magnetic 18.22 334.65 841.8 281.73 Body 4 6.5 4.8 1.2 1.4986 T-shaped 50.79 481.70 397.9 191.67 428.10 27.04% Magnetic Core Magnetic 17.51 306.03 772.6 236.43 Body 5 7.5 4.8 1.2 1.1256 T-shaped 38.3 262.56 450.6 118.31 388.46 30.62% Magnetic Core Magnetic 18.98 366.9 736.3 270.15 Body 6 6 4.8 1.2 1.7587 T-shaped 54.95 570.54 373.11 212.87 408.55 25.35% Magnetic Core Magnetic 15.67 238.64 819.96 195.67 Body 7 5.5 4.8 1.2 2.093 T-shaped 65.96 845.01 351.59 297.10 483.24 23.89% Magnetic Core Magnetic 15.35 227.85 816.99 186.15 Body 8 5.7 4.8 1.2 1.9487 T-shaped 60.42 699.78 359.97 251.90 442.22 24.46% Magnetic Core Magnetic 15.64 237.59 801.03 193.20 Body

(41) As shown in TABLE 6, when the ratio of the volume V1 of the base 21 to the volume V2 of the pillar 22 (V1/V2) is equal to or smaller than 2.533, the total core loss of the choke 1 is 695.02 mW or less (i.e., V1/V22.533.fwdarw.total core loss695.02 mW). More preferably, when the ratio of the volume V1 of the base 21 to the volume V2 of the pillar 22 (V1/V2) is equal to or smaller than 2.093, the total core loss of the choke 1 is 483.24 mW or less (i.e., V1/V22.093.fwdarw.total core loss483.24 mW). As can be seen in TABLE 6, when the size of the choke is set, the smaller the ratio V1/V2, the smaller the total core loss of the choke.

(42) In addition, as shown in Example No. 5 in TABLE 6, the equivalent permeability of the choke is 40.73 with 30% deviation. In other words, the equivalent permeability of the choke is between 28.511 and 52.949. In particular, the equivalent permeability of the choke may be measured by (but not limited to) a vibrating samples magnetometer (VSM) or determined by (but not limited to) measuring the dimension of the choke, the length and diameter of the wire coil, the wiring manner of the wire coil, and the inductance of the choke, applying the above-noted measurement to simulation software such as ANSYS Maxwell, Magnetics Designer, MAGNET, etc.

(43) FIG. 6 illustrates a relationship between the permeability C of the annealed T-shaped magnetic core 2 and the permeability B of the magnetic body 4 based on Example No. 5 in TABLE 6. This relationship is obtained based on the target inductance of the choke 1 of Example No. 5 in TABLE 6 with 30% deviation and different center permeabilities CC of the annealed T-shaped magnetic core 2 with 20% deviation (see TABLES 7-11).

(44) TABLE-US-00007 TABLE 7 100% of Target Inductance & 100% of Permeability .sub.C (i.e., .sub.C = .sub.CC) .sub.C .sub.B 60 27.5 75 23.98 90 21.66 125 18.93 150 17.94 200 16.80

(45) TABLE-US-00008 TABLE 8 70% of Target Inductance (30% deviation) & 80% of Permeability .sub.C (20% deviation) .sub.C .sub.B 48 16.52 60 14.50 72 13.32 100 11.79 120 11.21 160 10.49

(46) TABLE-US-00009 TABLE 9 130% of Target Inductance (+30% deviation) & 80% of Permeability .sub.C (20% deviation) .sub.C .sub.B 48 64.74 60 47.98 72 39.50 100 31.69 120 28.86 160 25.81

(47) TABLE-US-00010 TABLE 10 70% of Target Inductance (30% deviation) & 120% of Permeability .sub.C (+20% deviation) .sub.C .sub.B 72 13.32 90 12.21 108 11.52 150 10.61 180 10.26 240 9.85

(48) TABLE-US-00011 TABLE 11 130% of Target Inductance (+30% deviation) & 120% of Permeability .sub.C (+20% deviation) .sub.C .sub.B 72 39.50 90 33.76 108 30.05 150 26.33 180 25.02 240 23.31

(49) Therefore, as long as the permeability C of the annealed T-shaped magnetic core 2 and the permeability B of the magnetic body 4 are located at any point within the range as shown in FIG. 6, the choke having the target inductance with 30% deviation can be achieved. For example, when the permeability C of the annealed T-shaped magnetic core 2 is 48, the permeability B of the magnetic body 4 can be between 16.52 and 64.74; when the permeability C of the annealed T-shaped magnetic core 2 is 60, the permeability B of the magnetic body 4 can be between 14.50 and 47.98; when the permeability C of the annealed T-shaped magnetic core 2 is 240, the permeability B of the magnetic body 4 can be between 9.85 and 23.31 (see TABLE 12 below). As can be seen in FIG. 6 and TABLE 12, the higher the permeability C is, the smaller the range of the permeability B is, and the lower the upper limit and the lower limit of the permeability B are.

(50) TABLE-US-00012 TABLE 12 .sub.C .sub.B 48 16.52-64.74 60 14.50-47.98 72 13.32-39.50 90 12.21-33.76 100 11.79-31.69 108 11.52-30.05 120 11.21-28.86 150 10.61-26.33 160 10.49-25.81 180 10.26-25.02 240 9.85-23.31

(51) FIG. 7 illustrates the efficiency comparison between the choke 1 in Example No. 5 of TABLE 6 and a conventional choke with a toroidal core. In particular, the choke 1 in Example No. 5 of TABLE 6 has the annealed T-shaped magnetic core 2 made of annealed FeSiAl alloy powder (Sendust) with the permeability of 60 and the magnetic body 4 made of iron-based amorphous powder with the permeability of 27.5, and the dimension of the choke is 14.514.57 mm3. On the other hand, the conventional choke with a toroidal core made of FeSiAl alloy powder (Sendust) with the permeability of 60 and the dimension of the conventional choke is 171712 mm3 (max). TABLE 13 also shows the performance of the choke 1 in Example No. 5 of TABLE 6 and the conventional choke with the toroidal core.

(52) TABLE-US-00013 TABLE 13 Power Power Current Loss Loss DCR (A)@ L.sub.sat = (mw) @ (mw) @ Dimension L.sub.0 (H) (m) 4.1 H 2 A 10.5 A Conventional 17 17 12 mm.sup.3 6.91 6.35 11.8 485.3 1360.5 Choke with (max) Toroidal Core Choke with 14.5 14.5 7 mm.sup.3 6.43 5.9 21.8 412.06 1221.8 Annealed T-shaped Magnetic Core (Example No. 5 in TABLE 6)

(53) As can be seen in FIG. 7 and TABLE 13, the efficiency (higher saturation current and lower power loss at heavy load) of the choke 1 with an annealed T-shaped magnetic core 2 is significantly higher than the conventional choke with a toroidal core. Therefore, the choke with an annealed T-shaped magnetic core provides a superior solution for high saturation current at heavy load and low core loss at light load.

(54) The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.