MAGNETIC COMPONENT AND MAGNETIC BODY THEREOF

Abstract

A magnetic component includes a magnetic body and a coil. The magnetic body includes an inner leg, at least one outer leg, a first bottom portion and a second bottom portion. The inner leg and the at least one outer leg protrude from the first bottom portion and the second bottom portion. A cross-sectional area of the inner leg is larger than a total cross-sectional area of the at least one outer leg. The coil is wound around the inner leg.

Claims

1. A magnetic component comprising: a magnetic body comprising an inner leg, at least one outer leg, a first bottom portion and a second bottom portion, the inner leg and the at least one outer leg protruding from the first bottom portion and the second bottom portion, a cross-sectional area of the inner leg being larger than a total cross-sectional area of the at least one outer leg; and a coil wound around the inner leg.

2. The magnetic component of claim 1, wherein the cross-sectional area of the inner leg is larger than an effective cross-sectional area of the magnetic body, a number of the at least one outer leg is equal to N, N is a positive integer, the effective cross-sectional area is obtained by Aeff=(A1*V1+A2_1*V2_1+A2_2*V2_2+A3_1*V3_1+ . . . +A3_N*V3_N)/((V1*N+V2_1+V2_2+V3_1+ . . . +V3_N)/N), wherein Aeff represents the effective cross-sectional area, A1 represents the cross-sectional area of the inner leg, A2_1 represents a cross-sectional area of the first bottom portion, A2_2 represents a cross-sectional area of the second bottom portion, A3_N represents a cross-sectional area of an N-th outer leg of the at least one outer leg, V1 represents a volume of the inner leg, V2_1 represents a volume of the first bottom portion, V2_2 represents a volume of the second bottom portion, and V3_N represents a volume of the N-th outer leg of the at least one outer leg.

3. The magnetic component of claim 1, wherein the cross-sectional area of the inner leg is larger than a total cross-sectional area of the first bottom portion and the second bottom portion.

4. The magnetic component of claim 3, wherein the first bottom portion comprises a heat dissipating surface for in contact with a heat dissipating module for heat dissipation and a cross-sectional area of the first bottom portion is smaller than a cross-sectional area of the second bottom portion.

5. The magnetic component of claim 1, wherein a height of the magnetic body is between 22 mm and 152 mm.

6. The magnetic component of claim 1, wherein a ratio between the cross-sectional area of the inner leg and the total cross-sectional area of the at least one outer leg is between 1.01 and 1.6.

7. The magnetic component of claim 1, wherein a magnetic flux generated by the coil wound around the inner leg passes through cross-sectional areas of the inner leg, the first bottom portion, the at least one outer leg and the second bottom portion in sequence.

8. The magnetic component of claim 1, wherein the magnetic body comprises a plurality of outer legs, the inner leg is disposed between the outer legs, and the cross-sectional area of the inner leg is larger than the total cross-sectional area of the outer legs.

9. The magnetic component of claim 1, wherein a length-to-width ratio of the inner leg is between 1 and 10, and a length-to-width ratio of the at least one outer leg is between 1 and 10.

10. The magnetic component of claim 1, wherein the cross-sectional area of the inner leg is a minimum value along a height direction of the inner leg and the total cross-sectional area of the at least one outer leg is a minimum value along a height direction of the at least one outer leg.

11. The magnetic component of claim 1, wherein the cross-sectional area of the inner leg is identical along a height direction of the inner leg and the total cross-sectional area of the at least one outer leg is identical along a height direction of the at least one outer leg.

12. The magnetic component of claim 1, wherein there is no coil wound around the at least one outer leg.

13. A magnetic body comprising: an inner leg; at least one outer leg, a cross-sectional area of the inner leg being larger than a total cross-sectional area of the at least one outer leg; and a bottom portion, the inner leg and the at least one outer leg protruding from the bottom portion.

14. The magnetic body of claim 13, wherein the cross-sectional area of the inner leg is larger than an effective cross-sectional area of the magnetic body.

15. The magnetic body of claim 13, wherein the cross-sectional area of the inner leg is larger than two times a cross-sectional area of the bottom portion.

16. The magnetic body of claim 13, wherein a height of the magnetic body is between 11 mm and 76 mm.

17. The magnetic body of claim 13, wherein the core comprises a plurality of outer legs, the inner leg is disposed between the outer legs, and the cross-sectional area of the inner leg is larger than or equal to the total cross-sectional area of the outer legs.

18. The magnetic body of claim 13, wherein a length-to-width ratio of the inner leg is between 1 and 10, and a length-to-width ratio of the at least one outer leg is between 1 and 10.

19. The magnetic body of claim 13, wherein a ratio between the cross-sectional area of the inner leg and the total cross-sectional area of the at least one outer leg is between 1.01 and 1.6.

20. The magnetic body of claim 13, wherein the cross-sectional area of the inner leg is identical along a height direction of the inner leg and the total cross-sectional area of the at least one outer leg is identical along a height direction of the at least one outer leg.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a cross-sectional view illustrating a magnetic component according to an embodiment of the invention.

[0009] FIG. 2 is a perspective view illustrating a core shown in FIG. 1.

[0010] FIG. 3 is a top view illustrating the core shown in FIG. 2.

[0011] FIG. 4 is a side view illustrating the magnetic component shown in FIG. 1.

[0012] FIG. 5 is a front view illustrating the core shown in FIG. 2.

[0013] FIG. 6A is a perspective view illustrating a range of a volume of an inner leg shown in FIG. 5.

[0014] FIG. 6B is a perspective view illustrating the ranges of volumes of a first bottom portion and a second bottom portion shown in FIG. 5.

[0015] FIG. 6C is a perspective view illustrating the ranges of volumes of two outer legs shown in FIG. 5.

[0016] FIG. 7 is a perspective view illustrating a magnetic body according to another embodiment of the invention.

[0017] FIG. 8 is a perspective view illustrating a magnetic body according to another embodiment of the invention.

DETAILED DESCRIPTION

[0018] Referring to FIGS. 1 to 6C, FIG. 1 is a cross-sectional view illustrating a magnetic component 1 according to an embodiment of the invention, FIG. 2 is a perspective view illustrating a core 10a shown in FIG. 1, FIG. 3 is a top view illustrating the core 10a shown in FIG. 2, FIG. 4 is a side view illustrating the magnetic component 1 shown in FIG. 1, FIG. 5 is a front view illustrating the core 10a shown in FIG. 2, FIG. 6A is a perspective view illustrating a range of a volume V1 of an inner leg 100 shown in FIG. 5, FIG. 6B is a perspective view illustrating the ranges of volumes V2_1, V2_2 of a first bottom portion 104 and a second bottom portion 106 shown in FIG. 5, and FIG. 6C is a perspective view illustrating the ranges of volumes V3_1, V3_2 of two outer legs 102 shown in FIG. 5.

[0019] The magnetic component 1 of the invention may be a reactor, a transformer, an inductor or other magnetic components. As shown in FIG. 1, the magnetic component 1 comprises a magnetic body 10 and a coil 12. The magnetic body 10 comprises an inner leg 100, at least one outer leg 102, a first bottom portion 104 and a second bottom portion 106. Preferably, the first bottom portion 104 and the second bottom portion 106 may be plate structures and the magnetic body 10 may be a symmetric structure. The magnetic body 10 may be formed in one-piece or consists of a plurality of cores. In this embodiment, the magnetic body 10 may consist of two E cores 10a, 10b, but the invention is not so limited. The number and type of the cores of the magnetic body 10 may be determined according to practical applications. For example, the core of the magnetic body 10 may be E core, EFD core, EPC core, PQ core, EC core, low profile core, POT core, ETD core, EP core, RM core, solid center post RM core, and so on. In this embodiment, the cores 10a, 10b have identical structure and FIGS. 2 and 3 only show the core 10a for illustration purpose. However, in another embodiment, the cores 10a, 10b may have different structures.

[0020] In this embodiment, the magnetic body 10 may comprise a plurality of outer legs 102, but the invention is not so limited. As shown in FIG. 1, the magnetic body 10 comprises two outer legs 102 and the inner leg 100 is disposed between the two outer legs 102, wherein the inner leg 100 and the two outer legs 102 protrude from the first bottom portion 104 and the second bottom portion 106. In this embodiment, the core 10a comprises a part of the inner leg 100, parts of the two outer legs 102 and the first bottom portion 104, and the core 10b comprises a part of the inner leg 100, parts of the two outer legs 102 and the second bottom portion 106. However, in another embodiment, the cores 10a, 10b may also have one single outer leg 102 according to practical applications.

[0021] In this embodiment, the coil 12 is wound around the inner leg 100 and there is no coil wound around the outer leg 102. A magnetic flux MF generated by the coil 12 wound around the inner leg 100 passes through cross-sectional areas of the inner leg 100, the first bottom portion 104, the outer leg 102 and the second bottom portion 106 in sequence. Furthermore, a gap may exist between the inner legs 100 or/and the outer legs 102 of the cores 10a, 10b according to practical applications.

[0022] In this embodiment, a cross-sectional area of the inner leg 100 is larger than a total cross-sectional area of the outer leg 102. As shown in FIG. 3, the cross-sectional area of the inner leg 100 is defined as A1, and the cross-sectional areas of the two outer legs 102 are defined as A3_1, A3_2. Thus, the cross-sectional areas of the inner leg 100 and the two outer legs 102 conform to the following inequality: A1>A3_1+A3_2. It should be noted that the aforesaid inequality (A1>A3_1+A3_2) is adapted to the magnetic body 10 with two outer legs 102. When the structure of the magnetic body 10 conforms to the aforesaid geometric criteria, the magnetic body 10 can uniformize magnetic field distribution and then avoid heat accumulation to improve thermal balance for the magnetic component 1.

[0023] It should be noted that the number of the at least one outer leg 102 may be equal to N (N is a positive integer) and the cross-sectional areas of the inner leg 100 and the cross-sectional areas of the N outer legs 102 may be defined as A3_1, . . . , A3_N. Thus, the N outer legs 102 conform to the following inequality: A1>A3_1+ . . . +A3_N. In another embodiment, if the number of the at least one outer leg 102 is equal to 1, the cross-sectional areas of the inner leg 100 and the outer leg 102 conform to the following inequality: A1>A3_1. In another embodiment, if the number of the at least one outer leg 102 is equal to 4, the cross-sectional areas of the inner leg 100 and the four outer legs 102 conform to the following inequality: A1>A3_1+A3_2+A3_3+A3_4.

[0024] In this embodiment, the cross-sectional area of the inner leg 100 is larger than the total cross-sectional area of the two outer legs 102. Preferably, from the viewing angle shown in FIG. 3, a length-to-width ratio L1/W1 of the inner leg 100 is between 1 and 10, and a length-to-width ratio L2/W2 of the outer leg 102 is between 1 and 10. In another embodiment, the length-to-width ratio L1/W1 of the inner leg 100 may be between 1 and 8, and the length-to-width ratio L2/W2 of the outer leg 102 may be between 1 and 8. In this embodiment, a height of the magnetic body 10 may be between 22 mm and 152 mm (i.e. the height of each of the two cores 10a, 10b may be between 11 mm and 76 mm). Accordingly, the effect of the invention may be more outstanding.

[0025] In another embodiment, the cross-sectional area of the inner leg 100 may be further larger than an effective cross-sectional area of the magnetic body 10. When a number of the at least one outer leg 102 is equal to N (N is a positive integer), the effective cross-sectional area of the magnetic body 10 may be obtained by Aeff=(A1*V1+A2_1*V2_1+A2_2*V2_2+A3_1*V3_1+ . . . +A3_N*V3_N)/((V1*N+V2_1+V2_2+V3_1+ . . . +V3_N)/N), wherein Aeff represents the effective cross-sectional area, A1 represents the cross-sectional area of the inner leg 100 (as shown in FIG. 3), A2_1 represents a cross-sectional area of the first bottom portion 104 (as shown in FIG. 4), A2_2 represents a cross-sectional area of the second bottom portion 106 (as shown in FIG. 4), A3_N represents a cross-sectional area of an N-th outer leg of the N outer legs 102 (as shown in FIG. 3), V1 represents a volume of the inner leg 100 (as shown in FIGS. 5 and 6A), V2_1 represents a volume of the first bottom portion 104 (as shown in FIGS. 5 and 6B), V2_2 represents a volume of the second bottom portion 106 (as shown in FIGS. 5 and 6B), and V3_N represents a volume of the N-th outer leg of the N outer legs 102 (as shown in FIGS. 5 and 6C). In this embodiment, the number of the at least one outer leg 102 is equal to 2 (i.e. N=2), so Aeff=(A1*V1+A2_1*V2_1+A2_2*V2_2+A3_1*V3_1+A3_2*V3_2)/((V1*2+V2_1+V2_2+V3_1+V3_2)/2). In another embodiment, if the number of the at least one outer leg 102 is equal to 1 (i.e. N=1), Aeff=(A1*V1+A2_1*V2_1+A2_2*V2_2+A3_1*V3_1)/((V1*1+V2_1+V2_2+V3_1)/1). In another embodiment, if the number of the at least one outer leg 102 is equal to 4 (i.e. N=4), Aeff=(A1*V1+A2_1*V2_1+A2_2*V2_2+A3_1*V3_1+A3_2*V3_2+A3_3*V3_3+A3_4*V3_4)/((V1*4+V2_1+V2_2+V3_1+V3_2+V3_3+V3_4)/4).

[0026] In this embodiment, for example, provided that A1 is equal to 530 mm.sup.2, A2_1 is equal to 262 mm.sup.2, A2_2 is equal to 220 mm.sup.2, A3_1 is equal to 260 mm.sup.2, A3_2 is equal to 220 mm.sup.2, V1 is equal to 14861 mm.sup.3, V2_1 is equal to 6064 mm.sup.3, V2_2 is equal to 5091.9 mm.sup.3, V3_1 is equal to 4974 mm.sup.3, and V3_2 is equal to 4208.8 mm.sup.3, Aeff will be equal to 511.56 mm.sup.2 through the aforesaid equation. When the structure of the magnetic body 10 further conforms to the aforesaid geometric criteria, the magnetic body 10 can also uniformize magnetic field distribution and then avoid heat accumulation to improve thermal balance for the magnetic component 1. In the aforesaid inequality and equation, when A2_1 is equal to A2_2 or/and A3_1 is equal to A3_2, the thermal stress will be further reduced.

[0027] In another embodiment, the cross-sectional area of the inner leg 100 may be further larger than a total cross-sectional area of the first bottom portion 104 and the second bottom portion 106. As shown in FIG. 3, the cross-sectional area of the inner leg 100 is defined as A1. As shown in FIG. 4, the cross-sectional area of the first bottom portion 104 is defined as A2_1 and the cross-sectional area of the second bottom portion 106 is defined as A2_2. Thus, the cross-sectional areas of the inner leg 100, the first bottom portion 104 and the second bottom portion 106 conform to the following inequality: A1>A2_1+A2_2. It should be noted that the cross-sectional area of the inner leg 100 may also be equal to the total cross-sectional area of the first bottom portion 104 and the second bottom portion 106 (i.e. A1=A2_1+A2_2), but it is preferred to use A1>A2_1+A2_2. Furthermore, if the first bottom portion 104 and the second bottom portion 106 have identical cross-sectional area, the cross-sectional area of the inner leg 100 will be larger than two times the cross-sectional area of the first bottom portion 104 or the second bottom portion 106 (i.e. A1>2*A2_1 or A1>2*A2_2). When the structure of the magnetic body 10 conforms to the aforesaid geometric criteria, the magnetic body 10 can uniformize magnetic field distribution and then avoid heat accumulation to improve thermal balance for the magnetic component 1.

[0028] Referring to tables 1 and 2 below, tables 1 and 2 show several effect comparisons between the original structure and the improved structure of the invention. In table 2, AB represents differential magnetic distribution and ΔT represents differential temperature, wherein AB is the difference between the magnetic field density B1 of the inner leg 100 and the magnetic field density B3 of the outer leg 102. As shown in tables 1 and 2, it is obvious that the invention can uniformize magnetic field distribution and then avoid heat accumulation to improve thermal balance for the magnetic component 1 indeed.

TABLE-US-00001 TABLE 1 Aeff A1 A2_1 A2_2 A3_1 A3_2 Example 1 Original 540 508 288 288 254 254 structure Improved 509 508 285 285 160 160 structure Example 2 Original 535 457 305 305 261.5 261.6 structure Improved 553 542 312 312 223 223 structure Example 3 Original 540 510 280 280 260 260 structure Improved 526 530 262 262 260 260 structure Example 4 Original 527 457 288 288 262 262 structure Improved 545 542 255 255 291 291 structure Example 5 Original 527 457 288 288 262 262 structure Improved 531 542 289 289 223 223 structure

TABLE-US-00002 TABLE 2 After 10 A1/ A1/ minutes (A2_1 + (A3_1 + ΔB= Geometric A2_2) A3_2) B1 − B3 ΔT criteria Example 1 Original 0.88 1.00 42.5 8 A1 = (A3_1 + structure A3_2) Improved 0.89 1.59 −28.2 1 A1 > (A3_1 + structure A3_2) A1≈Aeff B1 < B3 Example 2 Original 0.75 0.87 14 36 structure Improved 0.87 1.22 −13.45 15 A1 > (A3_1 + structure A3_2) B1 < B3 Example 3 Original 0.91 0.98 42.5 110 structure Improved 1.01 1.02 34.55 70 A1 > (A2_1 + structure A2_2) A1 > (A3_1 + A3_2) A1 > Aeff Example 4 Original 0.79 0.87 14 36 structure Improved 1.06 0.93 6.6 20 A1 > (A2_1 + structure A2_2) Example 5 Original 0.79 0.87 14 36 structure Improved 0.94 1.22 −13.45 15 A1 > (A3_1+ structure A3_2) A1 > Aeff B1 < B3

[0029] In table 2, ΔB is the difference between the magnetic field density B1 of the inner leg 100 and the magnetic field density B3 of the outer leg 102. Once the absolute value of ΔB (i.e. |ΔB|) decreases or B1 is smaller than B3, the differential temperature ΔT and the thermal stress will decrease correspondingly.

[0030] In another embodiment, the first bottom portion 104 or the second bottom portion 106 may comprise a heat dissipating surface for in contact with a heat dissipating module (not shown) for heat dissipation. If the heat dissipating surface of the first bottom portion 104 is in contact with a heat dissipating module for heat dissipation, the cross-sectional area of the first bottom portion 104 may be smaller than the cross-sectional area of the second bottom portion 106. Alternatively, if the heat dissipating surface of the second bottom portion 106 is in contact with a heat dissipating module (not shown) for heat dissipation and the cross-sectional area of the second bottom portion 106 may be smaller than the cross-sectional area of the first bottom portion 104.

[0031] Referring to FIGS. 7 and 8, FIG. 7 is a perspective view illustrating a magnetic body 10′ according to another embodiment of the invention and FIG. 8 is a perspective view illustrating a magnetic body 10″ according to another embodiment of the invention.

[0032] As shown in FIG. 7, the magnetic body 10′ comprises one outer leg 102. As shown in FIG. 8, the magnetic body 10″ comprises four outer legs 102. The thermal stress corresponding to the magnetic bodies 10, 10′ and 10″ may be reduced by 50%, 30% and 55% respectively. It should be noted that, for the magnetic body 10″ shown in FIG. 8, the cross-sectional area of the inner leg 100 is larger than the total cross-sectional area of the four outer legs 102. Furthermore, a ratio between the cross-sectional area of the inner leg 100 and the total cross-sectional area of the outer leg(s) 102 may be between 1.01 and 1.6, such that the thermal stress will be further reduced.

[0033] In an embodiment, the cross-sectional area of the inner leg 100 may be a minimum value along a height direction of the inner leg 100 (i.e. the direction of H shown in FIG. 1) and the total cross-sectional area of the two outer legs 102 may be a minimum value along a height direction of the two outer legs 102 (i.e. the direction of H shown in FIG. 1).

[0034] In another embodiment, the cross-sectional area of the inner leg 100 may be identical along a height direction of the inner leg 100 (i.e. the direction of H shown in FIG. 1) and the total cross-sectional area of the two outer legs 102 may be identical along a height direction of the two outer legs 102 (i.e. the direction of H shown in FIG. 1), such that the manufacturing cost can be reduced.

[0035] As mentioned in the above, the invention adjusts and optimizes the cross-sectional areas of the inner leg and the at least one outer leg of the magnetic body to improve the characteristics of the magnetic component. Specifically, the cross-sectional area of the inner leg is larger than the total cross-sectional area of the at least one outer leg. Furthermore, the cross-sectional area of the inner leg may be larger than the effective cross-sectional area of the magnetic body and/or the cross-sectional area of the inner leg may be larger than the total cross-sectional area of the first bottom portion and the second bottom portion. When the structure of the magnetic body conforms to the aforesaid geometric criteria, the magnetic body can uniformize magnetic field distribution and then avoid heat accumulation to improve thermal balance for the magnetic component.

[0036] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.