U.S. patent application number 15/987896 was filed with the patent office on 2018-12-13 for magnetic component.
The applicant listed for this patent is Delta Electronics (Shanghai) Co.,Ltd.. Invention is credited to Zhen-Rong HUANG, Zeng-Yi LU, Hao SUN, Hai-Jun YANG, Pei-Ai YOU.
Application Number | 20180358162 15/987896 |
Document ID | / |
Family ID | 62597332 |
Filed Date | 2018-12-13 |
United States Patent
Application |
20180358162 |
Kind Code |
A1 |
HUANG; Zhen-Rong ; et
al. |
December 13, 2018 |
MAGNETIC COMPONENT
Abstract
A magnetic component includes a magnetic core and a first
winding module. The magnetic core has two opposite openings and at
least one magnetic column. The first winding module has a plurality
of annular metal plates disposed around the at least one magnetic
column. Each of the annular metal plates has an electrical
connection end, an annular portion and a heat-dissipating end. The
electrical connection end and the heat-dissipation end are located
at the two opposite openings of the magnetic core respectively. A
thermal-dissipating area of the heat-dissipating end is greater
than a cross-sectional area of a connection portion between the
heat-dissipating end and the annular portion.
Inventors: |
HUANG; Zhen-Rong; (Shanghai,
CN) ; YOU; Pei-Ai; (Shanghai, CN) ; SUN;
Hao; (Shanghai, CN) ; YANG; Hai-Jun;
(Shanghai, CN) ; LU; Zeng-Yi; (Shanghai,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Delta Electronics (Shanghai) Co.,Ltd. |
Shanghai |
|
CN |
|
|
Family ID: |
62597332 |
Appl. No.: |
15/987896 |
Filed: |
May 23, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01F 27/2866 20130101;
H01F 27/2876 20130101; H01F 27/24 20130101; H02M 2001/327 20130101;
H01F 27/2847 20130101; H02M 1/32 20130101; H01F 27/22 20130101;
H01F 27/16 20130101; H01F 17/043 20130101; H01F 27/022
20130101 |
International
Class: |
H01F 27/22 20060101
H01F027/22; H01F 27/24 20060101 H01F027/24; H01F 27/28 20060101
H01F027/28; H02M 1/32 20060101 H02M001/32 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 8, 2017 |
CN |
201710427735.6 |
Sep 19, 2017 |
CN |
201710845847.3 |
Claims
1. A magnetic component comprising: a magnetic core having two
opposite openings and at least one magnetic column; and a first
winding module having a plurality of annular metal plates are
through by the at least one magnetic column, wherein each annular
metal plate has an electrical connection end, an annular portion,
and a heat-dissipating end, the electrical connection end and the
heat-dissipation end are located aligned with the two opposite
openings of the magnetic core respectively, a thermal dissipation
area of the heat-dissipating end is greater than a cross-sectional
area of a connection portion between the heat-dissipating end and
the annular portion.
2. The magnetic component of claim 1, wherein a cross-section of
the heat-dissipating end and the annular portion collectively
define an L-shaped cross-section.
3. The magnetic component of claim 1, wherein a cross-section of
the heat-dissipating end and the annular portion collectively
define a T-shaped cross-section.
4. The magnetic component of claim 1, wherein the heat-dissipating
end of each annular metal plate protrudes out of the aligned one of
the two opposite openings.
5. The magnetic component of claim 1, wherein a total sum of the
thermal dissipation areas of the first winding module is greater
than or equal to an area of the aligned one of the two opposite
openings.
6. The magnetic component of claim 1, wherein the heat-dissipating
ends of the annular metal plates are electrically insulated from
each other.
7. The magnetic component of claim 1, wherein each electrical
connection end has a barb structure, which engages a printed
circuit board.
8. The magnetic component of claim 1, wherein each annular metal
plate is a single coil of circuit.
9. The magnetic component of claim 1, wherein at least part of the
annular metal plates are electrically coupled with one another to
form multiple coils of circuit.
10. The magnetic component of claim 1, wherein each annular metal
plate is an annular cooper plate.
11. The magnetic component of claim 1, wherein the magnetic core
has an inner chamber within which a thermal resin is filled.
12. The magnetic component of claim 1, wherein each electrical
connection end has a protrusion portion that has a height.
13. The magnetic component of claim 1 further comprising a second
winding module, wherein the second winding module comprises a
plurality of bobbins, the annular metal plates and the bobbins are
alternately disposed within the magnetic core, wherein the second
winding module further comprises a plurality of coil wires wound
around each of the bobbins.
14. The magnetic component of claim 13, wherein each bobbin has a
plurality of wire management slots arranged symmetrically.
15. The magnetic component of claim 13, wherein each bobbin has a
convex position block, the electrical connection end of each
annular metal plate has a notch, the convex position block engages
the notch when the bobbins and the annular metal plates are
assembled within the magnetic core.
16. The magnetic component of claim 13, wherein the coil wires
constitute three layers insulated wires.
17. The magnetic component of claim 14, wherein each coil wire has
an end that is led through corresponding ones of the wire
management slots and electrically connected to a lead terminal.
18. The magnetic component of claim 14, wherein the magnetic
component is a transformer.
19. An automotive power supply comprising: a water-cooling metal
block having a concave portion; and the magnetic component of claim
1 installed within the concave portion, and the heat-dissipating
end of each annular metal plate thermally contacting the
water-cooling metal block.
20. The automotive power supply of claim 19 further comprising a
first printed circuit board coupled with the electrical connection
end of each annular metal plate.
21. The automotive power supply of claim 19 further comprising a
second printed circuit board coupled with the heat-dissipating end
of each annular metal plate.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to China Application Serial
Number 201710427735.6, filed Jun. 8, 2017 and 201710845847.3, filed
Sep. 19, 2017 which are herein incorporated by reference.
BACKGROUND
Field of Invention
[0002] The present invention relates to a magnetic component and,
more particularly, to a magnetic component implemented in an
automotive power supply.
Description of Related Art
[0003] The thermal design of the power supply module has been one
of the key considerations for power supply manufacturers,
especially in the high-power supply module. Once the power supply
module's temperature increases, the power conversion efficiency
will reduce, or even break down the devices, cause a fire and so
on.
[0004] In recent years, due to the rise of environmental awareness,
oil and electricity hybrid or pure electric vehicle market are
gradually increased, the power supply module applied in the
vehicles needs higher power conversion efficiencies, and the
overall module volume must be controlled within a predetermined
limit.
[0005] How to improve the cooling efficiency of the power supply
module in a limited volume, and contribute to the improvement of
power conversion efficiency, still needs more efforts.
SUMMARY
[0006] In one or more embodiments, a magnetic component includes a
magnetic core and a first winding module. The magnetic core has two
opposite openings and at least one magnetic column. The first
winding module has a plurality of annular metal plates disposed
around the at least one magnetic column. Each of the annular metal
plates has an electrical connection end, an annular portion and a
heat-dissipating end. The electrical connection end and the
heat-dissipation end are located at the two opposite openings of
the magnetic core respectively. A thermal-contact area of the
heat-dissipating end is greater than a cross-sectional area of a
connection portion between the heat-dissipating end and the annular
portion.
[0007] In one or more embodiments, a cross-section of the
heat-dissipating end and a part of the annular portion collectively
define an L-shaped cross-section.
[0008] In one or more embodiments, a cross-section of the
heat-dissipating end and a part of the annular portion collectively
define a T-shaped cross-section.
[0009] In one or more embodiments, the heat-dissipating end of each
annular metal plate protrudes out of the aligned one of the two
opposite openings.
[0010] In one or more embodiments, a total sum of the
thermal-contact areas of the first winding module is greater than
or equal to an area of the aligned one of the two opposite
openings.
[0011] In one or more embodiments, the heat-dissipating ends of the
annular metal plates are electrically spaced from each other.
[0012] In one or more embodiments, each electrical connection end
has an anti-extraction barb structure, which engages the printed
circuit board.
[0013] In one or more embodiments, each annular metal plate is a
single coil of circuit.
[0014] In one or more embodiments, at least part of the annular
metal plates are electrically coupled with one another to form
multiple coils of circuit.
[0015] In one or more embodiments, each annular metal plate is an
annular cooper plate.
[0016] In one or more embodiments, the magnetic core has an inner
chamber within which a thermal resin is filled.
[0017] In one or more embodiments, each electrical connection end
has a protrusion portion that has a height.
[0018] In one or more embodiments, the magnetic component further
includes a second winding module, wherein the second winding module
includes a plurality of bobbins, the annular metal plates and the
bobbins are alternately disposed within the magnetic core, wherein
the second winding module further includes a plurality of coil
wires wound around each of the bobbins.
[0019] In one or more embodiments, each bobbin has a plurality of
wire management slots arranged symmetrically.
[0020] In one or more embodiments, each bobbin has a convex
position block, the electrical connection end of each annular metal
plate has a cutout section, and the convex position block engages
the cutout section when the bobbins and the annular metal plates
are assembled within the magnetic core.
[0021] In one or more embodiments, the coil wires constitute three
stacked layers of wires.
[0022] In one or more embodiments, each coil wire has an end that
is led through corresponding ones of the wire management slots and
electrically connected to a lead terminal.
[0023] In one or more embodiments, the magnetic component is an
electric transformer.
[0024] In one or more embodiments, an automotive power supply
includes a water-cooling metal block and a magnetic component. The
water-cooling metal block has concave portion. The magnetic
component is installed within the concave portion. The
heat-dissipating end of each annular metal plate thermally contacts
the water-cooling metal block.
[0025] In one or more embodiments, the automotive power supply
further includes a first printed circuit board coupled with the
electrical connection end of each annular metal plate.
[0026] In one or more embodiments, the automotive power supply
further incudes a second printed circuit board coupled with the
heat-dissipating end of each annular metal plate.
[0027] In sum, the magnetic component as discussed herein modify
the heat-dissipating end of the annular metal plate to have an
enlarged thermal dissipation area such that more areas can be
applied with heat pastes. When the magnetic component is
implemented on a high-power automotive power supply, the
heat-dissipation ability of the winding module can be effectively
risen by utilizing larger thermal dissipation area to dissipate
heat with the water-cooling metal block such that a compact
automotive power supply with high reliability and good heat
dissipation effect can be achieved.
[0028] It is to be understood that both the foregoing general
description and the following detailed description are by examples,
and are intended to provide further explanation of the invention as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention can be more fully understood by reading the
following detailed description of the embodiment, with reference
made to the accompanying drawings as follows:
[0030] FIG. 1 illustrates an exploded view of a magnetic component
according to one embodiment of the present disclosure;
[0031] FIG. 2 illustrates a cross-sectional view of an annular
metal plate in FIG. 1;
[0032] FIG. 3 illustrates a cross-sectional view of an annular
metal plate according to another embodiment of the present
disclosure;
[0033] FIG. 4 illustrates a perspective view of a second winding
module in FIG. 1;
[0034] FIG. 5 illustrates an exploded view of a magnetic component
according to another embodiment of the present disclosure;
[0035] FIG. 6 illustrates an enlarged view of the heat-dissipation
end in FIG. 5;
[0036] FIG. 7 illustrates an assembled view of the magnetic
component according to still another embodiment of the present
disclosure;
[0037] FIG. 8 illustrates an assembled view of the magnetic
component coupled to a water-cooling metal block according to
another embodiment of the present disclosure;
[0038] FIG. 9 illustrates an assembled view of an automotive power
supply according to one embodiment of the present disclosure;
and
[0039] FIG. 10 illustrates a perspective view to show a coil wire
of the magnetic component being coupled to a lead terminal
according to one embodiment of the present disclosure.
DETAILED DESCRIPTION
[0040] Reference will now be made in detail to the present
embodiments of the invention, examples of which are illustrated in
the accompanying drawings. Wherever possible, the same reference
numbers are used in the drawings and the description to refer to
the same or like parts.
[0041] An aspect of the present disclosure is to provide a magnetic
component utilized in an automotive power supply. The magnetic
component within the automotive power supply occupies a larger
volume, weight, and is also one of the main heat-generating
elements. The present disclosure will enhance its heat-dissipating
capacity as well as optimizing its power conversion efficiency.
[0042] FIG. 1 illustrates an exploded view of a magnetic component
100 according to one embodiment of the present disclosure. The
magnetic component 100 includes a magnetic core 102, a first
winding module 106 and a second winding module 107 (also referring
to FIG. 4). The magnetic core 102 includes two opposite openings
(104a, 104b) and at least one magnetic column 104c. In this
embodiment, the magnetic core 102 consists of two half magnetic
cores in mirror symmetry, but not being limited to. In this
embodiment, the magnetic core 102 may be iron oxide mixtures, such
as manganese-zinc ferrite, but other metal oxide materials can also
be applied on demand without limitation.
[0043] The first winding module 106 includes multiple annular metal
plates 108 that are inserted through by the magnetic column 104c.
Each annular metal plate 108 includes an electrical connection end
108a, an annular portion 108c and a heat-dissipating end 108b. The
electrical connection end 108a and the heat-dissipating end 108b
are located at (or aligned with) the two opposite openings (104a,
104b) of the magnetic core 102 after the magnetic component is
assembled. A thermal-dissipation area of the heat-dissipating end
108b is greater than a cross-sectional area of a connection portion
108d between the heat-dissipating end 108b and the annular portion
108c such that more thermal dissipation area can be applied with
heat paste. In this embodiment, the magnetic component 100 can be
an electric transformer, the first winding module 106 can be a
secondary winding of the electric transformer, and the second
winding module 107 can be a primary winding of the electric
transformer.
[0044] In this embodiment, the electrical connection end 108a has a
protrusion portion 108e that has a height H. The protrusion portion
108e is used to inserted into a printed circuit board, and the
height H may be varied to control an insulating gap between the
heat-dissipating end 108b and a bottom surface of a concave portion
126 (referring to FIG. 8).
[0045] In this embodiment, each annular metal plate 108 can be a
single coil of circuit, but the annular metal plates 108 can also
be electrically coupled with one another to form multiple coils of
circuit.
[0046] In this embodiment, each annular metal plate 108 can be an
annular cooper plate applied in the low-voltage high-current
automotive applications, but other metal materials can also be
applied according to actual demands.
[0047] In this embodiment, a total sum of the thermal dissipation
areas (at the heat-dissipating ends 108b) of the first winding
module 106 is greater than or equal to an area of the corresponding
opening 104b of the magnetic core 102 to assure a greater thermal
dissipation area and the heat-dissipating end 108b protruded out of
the opening 104b.
[0048] Reference is made to FIG. 2 and FIG. 3. FIG. 2 illustrates a
cross-sectional view of an annular metal plate in FIG. 1, and FIG.
3 illustrates a cross-sectional view of an annular metal plate
according to another embodiment of the present disclosure. As
illustrated in FIG. 2, a cross-section of the heat-dissipating end
108b and a cross-section of the annular portion 108c collectively
define an L-shaped cross-section. The L-shaped cross-section is
formed by bending the heat-dissipating end 108b or other
mold-manufactured to enlarge the thermal dissipation area. However,
the cross-section of the heat-dissipating end 108b and the
cross-section of the annular portion 108c is not limited to form an
L-shape, and any shapes capable of enlarging the thermal
dissipation area are applicable. For example, as illustrated in
FIG. 3, a cross-section of the heat-dissipating end 108b' and a
cross-section of the annular portion 108c of the annular metal
plate 108' collectively define a T-shaped cross-section.
[0049] In this embodiment, the heat-dissipating end 108b of the
annular metal plate 108 protrudes out of the corresponding opening
104b to be in thermal contact with a heat-dissipating device, e.g.,
a metallic water-cooling block. The electrical connection end 108a
of the annular metal plate 108 also protrudes out of the
corresponding opening 104a to be electrically coupled with a
printed circuit board.
[0050] Reference is made to FIG. 4 and FIG. 10. FIG. 4 illustrates
a perspective view of a second winding module in FIG. 1. FIG. 10
illustrates a perspective view to show a coil wire of the magnetic
component being coupled to a lead terminal according to one
embodiment of the present disclosure. The second winding module 107
includes multiple bobbins 107a, and the annular metal plates 108
and the bobbins 107a are alternately arranged within an inner
chamber of the magnetic core 102. The second winding module 107
includes multiple coil wires 107b wound within a coil cavity 107c
of each bobbin 107a. In this embodiment, the coil wires 107b are
three layers insulated wires (electrically-conductive wire with
insulated sheath). The bobbin 107a is made from electrical
insulating materials such that the annular metal plates 108 can be
electrical insulated by the bobbins 107a after they are assembled
within the magnetic core 102. When the magnetic component 100
serves as a transformer, a quantity and turns of the coil wires
107b and the annular metal plates 108 can be varied to achieve a
desired voltage according to actual demands. In this embodiment,
each bobbin 107a also has a plurality of wire management slots 107d
arranged symmetrically. The coil wires 107b have their ends 107b1
led through corresponding ones of the wire management slots 107d
and electrically connected to a lead terminal 150.
[0051] In this embodiment, each bobbin 107a has a convex position
block 107e, and the electrical connection end 108a has a notch
108f, and the convex position block 107e engages the notch 108f
when the bobbins 107a and the annular metal plates 108 are
assembled within the magnetic core 102.
[0052] Reference is made to FIG. 5. FIG. 5 illustrates an exploded
view of a magnetic component according to another embodiment of the
present disclosure. The magnetic component 100a is different from
the magnetic component 100 in that each coil of the magnetic
component comprises two turns constituted by two annular metal
plates 108. In particular, two annular metal plates 108 are
overlapped and insulated by an insulation sheet 113. When each coil
of the magnetic component comprises two turns constituted by two
annular metal plates 108, each heat-dissipating end 108b has a
smaller thermal dissipation area, i.e., compared with the thermal
dissipation area of the annular metal plate 108 in FIG. 1, the
heat-dissipating ends 108b are electrically insulated, e.g. by the
insulation sheet 113. FIG. 5 only illustrates each coil of the
magnetic component comprises two turns constituted by two annular
metal plates 108, but the coil of the magnetic component may
comprise more turns constituted by the annular metal plates
108.
[0053] Reference is made to FIG. 6. FIG. 6 illustrates an enlarged
view of the heat-dissipation end 108a in FIG. 5. Each electrical
connection ends of the two annular metal plates 108 has a barb
structure 110 that has an anti-extraction functionality. The two
barb structures 110 of the two annular metal plates 108 faces away
from each other and not overlapped or aligned in position. In this
embodiment, the barb structure 110 is formed by punching onto one
surface of the annular metal plate 108 to form a convex portion on
an opposite surface of the annular metal plate 108, but the
manufacturing method is not limited to this way. The barb structure
110 is configured to engage inside the printed circuit board to
prevent from easy extraction.
[0054] Reference is made to FIG. 7. FIG. 7 illustrates an assembled
view of the magnetic component 100a in FIG. 5. When the first
winding module 106 and the second winding module 107 are
alternately arranged (as illustrated in FIG. 4) and assembled, and
installed into an inner chamber 102a of the magnetic core 102 as
illustrated in FIG. 7. In this embodiment, the magnetic component
may have a thermal resin 140 filled into the inner chamber 102a of
the magnetic core 102, so as to fill into all air gaps among the
first winding module 106 and the second winding module 107, thereby
enhancing the heat-dissipating efficiency of the first winding
module 106 and the second winding module 107. After the magnetic
component is assembled, the heat-dissipating end 108b protrudes out
of the corresponding opening 104b to be thermal contact with a
heat-dissipating device, e.g., a water-cooling metal block, while
the electrical connection end 108a also protrudes out of the
corresponding opening 104a to be coupled with a printed circuit
board.
[0055] Reference is made to FIG. 8 and FIG. 10. FIG. 8 illustrates
an assembled view of the magnetic component coupled to a
water-cooling metal block according to another embodiment of the
present disclosure. When all components of the magnetic component
(100a or 100) are assembled, the heat-dissipating end 108b is used
to thermally contact a water-cooling metal block 120. In this
embodiment, the water-cooling metal block 120 has a liquid-cooling
circulation passage inside thereof, and a water-cooling liquid is
circulated through an inlet 124a and an outlet 124b. The
water-cooling metal block 120 also has a concave portion 126 to
accommodate the magnetic component (100a or 100), and the
heat-dissipating end 108b of the magnetic component (100a or 100)
is in thermal contact with a bottom surface of the concave portion
126. In another embodiment, the concave portion 126 may also be
filled with a thermal resin, e.g., between the heat-dissipating end
108b and the bottom surface of the concave portion 126. In this
embodiment, each bobbin 107a also has a plurality of wire
management slots 107d arranged symmetrically. The coil wires 107b
have their ends 107b1 led through corresponding ones of the wire
management slots 107d and electrically connected to a lead terminal
150. The lead terminal 150 is accommodated in another concave
portion 127 adjacent to a side of the magnetic component (100a or
100).
[0056] Reference is made to FIG. 9. FIG. 9 illustrates an assembled
view of an automotive power supply 200 according to one embodiment
of the present disclosure. After the magnetic component (100a or
100) is assemble to the water-cooling metal block 120 and other
associated electronic components are installed, a printed circuit
board 130 can be attached upon. And the electrical connection end
108a of the magnetic component (100a or 100) is inserted into a
connection hole of the printed circuit board 130, and fasteners
132, e.g., screws, are used to secure the printed circuit board 130
to the water-cooling metal block 120 and the magnetic component
(100a or 100). The height H of the protrusion portion 108e may be
varied to control an insulating gap between the heat-dissipating
end 108b and a bottom surface of the concave portion 126 (referring
to FIG. 8).
[0057] As discussed above, the annular metal plate 108 of the
magnetic component (100a or 100) has its electrical connection end
for an electrical coupling function and its heat-dissipating end
for a thermal dissipation function. However, the heat-dissipating
end of the annular metal plate may be used both for the electrical
coupling function and the thermal dissipation function. For
example, the heat-dissipating end of the annular metal plate, e.g.,
the heat-dissipating end 108b, is coupled to a printed circuit
board equipped with excellent heat-dissipating efficiency, e.g.,
the printed circuit board equipped with heat-dissipating fins. The
thermal dissipation area at heat-dissipating end is expanded to
improve thermal performance and the heat-dissipating end also
serves as an electrical connection interface to the printed circuit
board.
[0058] In sum, the magnetic component as discussed herein modify
the heat-dissipating end of the annular metal plate to have a
larger thermal dissipation area such that more areas can be applied
with heat pastes. When the magnetic component is implemented on a
high-power automotive power supply, the heat-dissipation efficiency
of the winding module can be effectively solved by utilizing larger
thermal dissipation area to dissipate heat to the water-cooling
metal block such that a compact automotive power supply with high
reliability and good heat dissipation can be achieved.
[0059] Although the present invention has been described in
considerable detail with reference to certain embodiments thereof,
other embodiments are possible. Therefore, the spirit and scope of
the appended claims should not be limited to the description of the
embodiments contained herein.
[0060] It will be apparent to those skilled in the art that various
modifications and variations can be made to the structure of the
present invention without departing from the scope or spirit of the
invention. In view of the foregoing, it is intended that the
present invention cover modifications and variations of this
invention provided they fall within the scope of the following
claims.
* * * * *