Patent Application
20230223187
The invention relates to a magnetic component and, more particularly, to a magnetic component capable of effectively reducing leakage inductance.
A transformer is an important magnetic component used for increasing or decreasing voltage. Inmost of circuits, there is always a transformer installed therein. At present, the windings of the transformer used for large current are stacked with each other each other from top to bottom in a core, such that the windings cannot be fully coupled, thereby resulting in a problem of excessive leakage inductance, which increases magnetic interference and loss.
The invention provides a magnetic component capable of effectively reducing leakage inductance, so as to solve the aforesaid problems.
According to an embodiment of the invention, a magnetic component comprises a first core, a second core, an outer bobbin, a first winding, an inner bobbin and a second winding. The first core has a first inner surface. The second core is disposed on the first core. The second core has a second inner surface, wherein the second inner surface faces the first inner surface. The outer bobbin is disposed between the first core and the second core. The outer bobbin has a hollow tube portion, a first bottom portion and a first top portion. The first bottom portion and the first top portion are located at opposite sides of the hollow tube portion. The first winding is wound around outer side of the hollow tube portion. The inner bobbin is disposed in the hollow tube portion. The inner bobbin has a second bottom portion and a second top portion. The second winding is wound around the inner bobbin. The second bottom portion is exposed to bottom side of the first bottom portion, such that the first bottom portion overlaps the second bottom portion in a height direction of the magnetic component. The second top portion and the second bottom portion abut against inner side of the hollow tube portion.
As mentioned in the above, the first winding is wound around outer side of the hollow tube portion of the outer bobbin and the second winding is wound around the inner bobbin. When the inner bobbin is disposed in the hollow tube portion of the outer bobbin, the second winding is stacked with the first winding from inside to outside, such that the leakage inductance can be effectively reduced. Furthermore, since the second top portion and the second bottom portion of the inner bobbin abut against inner side of the hollow tube portion, the distance between the first winding and the second winding can be kept at a fixed value, so as to ensure the leakage inductance and the magnetizing inductance of the magnetic component. Moreover, since the first bottom portion of the outer bobbin overlaps the second bottom portion of the inner bobbin in the height direction of the magnetic component, the overall height of the magnetic component can be effectively reduced, such that the magnetic component of the invention is beneficial to be miniaturized.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
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The first core 10 has a first inner surface 100 and a first pillar 102, wherein the first pillar 102 protrudes from the first inner surface 100. The second core 12 has a second inner surface 120 and a second pillar 122, wherein the second pillar 122 protrudes from the second inner surface 120. In this embodiment, the first core 10 and the second core 12 are E cores, but the invention is not so limited. The types of the first core 10 and the second core 12 may be determined according to practical applications. The second core 12 is disposed on the first core 10, such that the second inner surface 120 faces the first inner surface 100 and the second pillar 122 is aligned with the first pillar 102.
The outer bobbin 14 is disposed between the first core 10 and the second core 12. The outer bobbin 14 has a hollow tube portion 140, a first bottom portion 142, a first top portion 144, a connecting portion 146, a first engaging portion 148 and an insulating portion 150. The first bottom portion 142 and the first top portion 144 are located at opposite sides of the hollow tube portion 140. Accordingly, when the outer bobbin 14 is disposed between the first core 10 and the second core 12, the first bottom portion 142 is close to the first core 10 and the first top portion 144 is close to the second core 12. The connecting portion 146 protrudes from a bottom of the outer bobbin 14 in the horizontal direction. In this embodiment, the hollow tube 140 has a winding outlet 152, wherein a position of the winding outlet 152 corresponds to a position of the connecting portion 146. In this embodiment, the winding outlet 152 extends to the first bottom portion 142 and the first engaging portion 148 is disposed at the bottom of the winding outlet 152, such that a position of the first engaging portion 148 also corresponds to the position of the connecting portion 146. The insulating portion 150 surrounds the hollow tube portion 140.
The inner bobbin 18 is disposed in the hollow tube portion 140 of the outer bobbin 14. The inner bobbin 18 has a second bottom portion 180, a second top portion 182 and a second engaging portion 184. The second bottom portion 180 and the second top portion 182 are located at opposite sides of the inner bobbin 18. Accordingly, when the inner bobbin 18 is disposed in the hollow tube portion 140 of the outer bobbin 14, the second bottom portion 180 is close to the first core 10 and the second top portion 182 is close to the second core 12. The second engaging portion 184 is disposed at the second bottom portion 180.
In this embodiment, the first engaging portion 148 of the outer bobbin 14 may be a recess and the second engaging portion 184 of the inner bobbin 18 may be a protrusion. However, in another embodiment, the first engaging portion 148 of the outer bobbin 14 may be a protrusion and the second engaging portion 184 of the inner bobbin 18 may be a recess. That is to say, according to practical applications, one of the first engaging portion 148 and the second engaging portion 184 may be a recess and the other one of the first engaging portion 148 and the second engaging portion 184 may be a protrusion. Furthermore, the shape of the first engaging portion 148 corresponds to the shape of the second engaging portion 184.
To assemble the magnetic component 1, the second winding 20 may be wound around the inner bobbin 18 first. Then, the inner bobbin 18 with the second winding 20 is disposed into the hollow tube portion 140 of the outer bobbin 14 by aligning and engaging the second engaging portion 184 with the first engaging portion 148, as shown in FIG. 3. In this embodiment, the inner bobbin may be wholly disposed within the hollow tube portion 140 of the outer bobbin 14. Since the first engaging portion 148 engages with the second engaging portion 184, the inner bobbin 18 can be stably disposed in the hollow tube portion 140 of the outer bobbin 14 without rotation. In this embodiment, the position of the first engaging portion 148 corresponds to the position of the connecting portion 146. When the second winding 20 is wound around the inner bobbin 18, the winding end (not shown) of the second winding 20 may be retained at a position corresponding to the second engaging portion 184. Accordingly, after the second engaging portion 184 is aligned and engaged with the first engaging portion 148, the winding end of the second winding 20 can be connected to the pins 1461 of the connecting portion 146 of the outer bobbin 14 through the winding outlet 152.
Then, the first winding 16 is wound around outer side of the hollow tube portion 140 of the outer bobbin 14, as shown in
Then, the first pillar 102 of the first core 10 and the second pillar 122 of the second core 12 are inserted into the inner bobbin 18 to complete the assembly of the magnetic component 1, as shown in
In this embodiment, a height H3 of the inner bobbin 18 is smaller than a height H4 of the outer bobbin 14. However, in another embodiment, the height H3 of the inner bobbin 18 may be equal to the height H4 of the outer bobbin 14. That is to say, the first top portion 144 of the outer bobbin 14 may be flush with the second top portion 182 of the inner bobbin 18, such that the first top portion 144 and the second top portion 182 may abut against the second inner surface 120 of the second core 12 simultaneously, so as to further miniaturize the magnetic component 1.
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As mentioned in the above, the first winding is wound around outer side of the hollow tube portion of the outer bobbin and the second winding is wound around the inner bobbin. When the inner bobbin is disposed in the hollow tube portion of the outer bobbin, the second winding is stacked with the first winding from inside to outside, such that the leakage inductance can be effectively reduced. Furthermore, since the second top portion and the second bottom portion of the inner bobbin abut against inner side of the hollow tube portion, the distance between the first winding and the second winding can be kept at a fixed value, so as to ensure the leakage inductance and the magnetizing inductance of the magnetic component. Moreover, since the first bottom portion of the outer bobbin overlaps the second bottom portion of the inner bobbin in the height direction of the magnetic component, the overall height of the magnetic component can be effectively reduced, such that the magnetic component of the invention is beneficial to be miniaturized. In addition, the invention may utilize the second engaging portion or the winding mark to indicate where the winding end of the second winding should be retained at according to whether the first engaging portion is staggered with the winding outlet.
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.
