JP-7856122-B2 - Magnetic components

JP7856122B2JP 7856122 B2JP7856122 B2JP 7856122B2JP-7856122-B2

Inventors

武藤高見

Assignees

株式会社村田製作所

Dates

Publication Date: 20260511
Application Date: 20240405
Priority Date: 20230407

Claims (20)

A magnetic component, A core including a first projection and a second projection extending in a first direction, A first conductor comprising a first flat wire, wherein the first flat wire defines a first turn portion extending around a first projection such that the minimum dimension of the first flat wire is parallel or substantially parallel to the first direction, A second conductor including a second flat wire, the second flat wire defining a second turn extending around the second projection such that the minimum dimension of the second flat wire is parallel or substantially parallel to the first direction, A magnetic component in which the first turn portion and the second turn portion are adjacent to each other, and are set to be offset in two dimensions so as to define a gap extending between adjacent turn portions of the first conductor and the second conductor within the core, such that the first turn portion and the second turn portion do not overlap when viewed from the first direction .
The magnetic component according to claim 1, wherein the first plane defined by the first turn portion and the second plane defined by the second turn portion are not on the same plane.
The first conductor includes a first foot and a second foot extending in opposite directions. The magnetic component according to claim 1, wherein the second conductor includes a first foot and a second foot extending in opposite directions.
The first turn section is either a single full turn section or a single three-quarter turn section. The magnetic component according to claim 1, wherein the second turn portion is either a single full turn portion or a single three-quarter turn portion.
The magnetic component according to any one of claims 1 to 4, wherein the core includes an upper core and a lower core.
A magnetic component, A core including a first projection and a second projection extending in a first direction, A first conductor comprising a first flat wire, wherein the first flat wire defines a first turn portion extending around a first projection such that the minimum dimension of the first flat wire is parallel or substantially parallel to the first direction, A second conductor including a second flat wire, the second flat wire defining a second turn extending around the second projection such that the minimum dimension of the second flat wire is parallel or substantially parallel to the first direction, The first turn portion and the second turn portion are adjacent to each other and are set to be offset in two dimensions so as to define a gap between the adjacent turn portions of the first conductor and the second conductor. The core includes an upper core and a lower core, The upper core includes an upper gap corner which is located between the adjacent turn portions and is the corner closest to the gap, The lower core includes a lower gap corner which is located between the adjacent turn portions and is the corner closest to the gap, The upper and lower gap corners of the magnetic component are chamfered.
The magnetic component according to claim 6, wherein both the upper component corner of the upper core opposite the upper gap corner and the lower component corner of the lower core opposite the lower gap corner are notched.
A magnetic component assembly, Upper circuit board and lower circuit board, A magnetic component assembly comprising a magnetic component according to any one of claims 1 to 4, mounted between the upper substrate and the lower substrate.
The magnetic component assembly according to claim 8, further comprising a first electronic component on the upper surface of the upper substrate.
The upper second electronic component attached to the lower surface of the upper substrate, The lower second electronic component is mounted on the upper surface of the lower substrate, The aforementioned core is An upper component corner portion adjacent to the upper substrate and cut out to accommodate the upper second electronic component, The magnetic component assembly according to claim 8, further comprising: a lower component corner portion adjacent to the lower substrate and cut out to accommodate the lower second electronic component.
A magnetic component, It is the core, An upper core including an upper surface and a lower surface not parallel to the upper surface, A lower core including an upper surface and a lower surface not parallel to the upper surface, wherein the upper surface of the upper core and the lower surface of the lower core are parallel or substantially parallel, A core including a first groove and a second groove extending through the core, A first conductor including a first flat wire, wherein the first flat wire extends through the first groove such that the minimum dimension of the first flat wire is not parallel to the minimum dimension of the core, A second conductor comprising a second flat wire, wherein the second flat wire extends through the second groove such that the minimum dimension of the second flat wire is not parallel to the minimum dimension of the core, A magnetic component in which the first groove and the second groove and the first conductor and the second conductor are arranged to define a gap between adjacent turned portions of the first conductor and the second conductor.
The magnetic component according to claim 11, wherein the first plane defined by the first conductor and the second plane defined by the second conductor lie on the same plane or substantially on the same plane.
The first conductor includes a first foot and a second foot extending in opposite directions. The magnetic component according to claim 11, wherein the second conductor includes a first foot and a second foot extending in opposite directions.
The magnetic component according to any one of claims 11 to 13, wherein the height of the gap is less than the height of at least one of the first conductor and the second conductor.
The magnetic component according to any one of claims 11 to 13, wherein the first groove and the second groove are contained within the upper core.
The magnetic component according to any one of claims 11 to 13, wherein the first groove and the second groove are contained within the lower core.
The upper surface of the upper core includes a notched upper component corner, The magnetic component according to any one of claims 11 to 13, wherein the lower surface of the lower core includes a notched lower component corner.
A magnetic component assembly, Upper circuit board and lower circuit board, A magnetic component assembly comprising a magnetic component according to any one of claims 11 to 13, mounted between the upper substrate and the lower substrate.
The magnetic component assembly according to claim 18, further comprising a first electronic component on the upper surface of the upper substrate.
The upper second electronic component attached to the lower surface of the upper substrate, The lower second electronic component is mounted on the upper surface of the lower substrate, The upper surface of the upper core includes an upper component corner cut out to accommodate the upper second electronic component, The magnetic component assembly according to claim 18, wherein the lower surface of the lower core includes a lower component corner cut out to accommodate the lower second electronic component.

Description

This invention relates to magnetic components. More specifically, it relates to a gap structure for a magnetic component that can be used to control leakage inductance. Magnetic components such as inductors or transformers are known to be embedded in converters. In magnetic components, leakage inductance enables the converter to function over a wide bandwidth or wide operating frequency. Conventional techniques cannot control the amount of leakage inductance. Leakage inductance can be generated in the gap within the magnetic core. This is a perspective view of a known magnetic component in which the turns of a flat wire coil lie on the same plane.This is a perspective view of a magnetic component according to a first exemplary embodiment of the present invention, in which the turned portions of the flat wire coil are not on the same plane.Figure 2 is a perspective view of the magnetic component, with the upper magnetic core shown as transparent.Figure 2 is a perspective view of the flat wire coil of the magnetic component.Figure 2 is a side view of the magnetic component.This is a perspective view of a magnetic component according to a second exemplary embodiment of the present invention, in which adjacent corners of the magnetic core are chamfered and the opposite corner is notched.Figure 6 is a perspective view of the magnetic component with the upper printed circuit board removed.Figure 7 is a perspective view of the magnetic component, with the upper magnetic core shown as transparent.Figure 6 is a side view of the magnetic component.This is a perspective view of a magnetic component according to a third exemplary embodiment of the present invention, in which the cross-section of the magnetic core is trapezoidal.Figure 10 is a perspective view of the magnetic component, with the upper magnetic core shown as transparent.Figure 10 is a side view of the magnetic component.This is a perspective view of a magnetic component according to a third exemplary embodiment of the present invention, in which the cross-section of the magnetic core is trapezoidal and the corner on the opposite side of the magnetic core is notched.Figure 13 is a perspective view of the magnetic component, with the upper magnetic core shown as transparent.Figure 13 is a side cross-sectional view of the magnetic component. Figures 2 to 5 show a magnetic component 10 according to a first exemplary embodiment of the present invention. The magnetic component 10 includes a conductor 11 and a core having an upper core 12 and a lower core 13. As shown in Figures 2 to 5, the magnetic component 10 may include four conductors 11, but any number of conductors 11 may be two or more. Each conductor 11 may be defined by a flat wire. Each conductor 11 may include copper, brass, or other suitable conductive materials. The width of the flat wire may be greater than the thickness of the flat wire. The conductor 11 may include two legs 11b connected by a turn 11a. The two legs 11b may extend in opposite directions (e.g., upward and downward) so that the conductor 11 can be connected to two opposing parallel substrates (not shown in Figures 2 to 5, but shown as an upper substrate 25 and a lower substrate 26 in Figures 6 to 9), or the two legs 11b may extend in the same direction so that the conductor 11 can be connected to the same substrate (not shown). The substrate may be, for example, a printed circuit board (PCB) or other suitable substrate. The magnetic component assembly may include the magnetic component 10 connected to one or two substrates. The projections 12a and 13a may extend from the upper core 12 or lower core 13 along the first direction. The number of projections 12a and 13a may be the same as the number of conductors 11. The projections 12a and 13a may have any preferred cross-sectional shape, including the rectangular cross-sectional shape shown in Figure 3. Each turn 11a of the conductor 11 may wrap around or extend around the corresponding projection 12a or 13a. As shown in Figures 3 and 4, the turn 11a may be a single turn, for example, including a single three-quarter turn or a single full turn. The surface of the flat wire of the turn 11a defined by the width direction is perpendicular or substantially perpendicular to the first direction within the manufacturing tolerance range and/or measurement tolerance range; that is, the thickness or minimum dimension of the flat wire is parallel or substantially parallel to the first direction within the manufacturing tolerance range and/or measurement tolerance range. In Figures 2, 3, and 5, the core may include two parts, namely the upper core 12 and the lower core 13, but any number of parts may be used. For example, the core may include a single part or three or more parts. The core, including the upper core 12 and the lower core 13, may be made of ferrite such as MnZn ferrite, or any other suitable magnetic material. In Figures 2 to 5, the protrusion 12a extends only from the lower core 1