MAGNETIC COMPONENT

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.

CROSS-REFERENCE TO RELATED APPLICATION

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

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

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.

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.

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

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.

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.

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.

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.

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.

In one or more embodiments, the heat-dissipating ends of the annular metal plates are electrically spaced from each other.

In one or more embodiments, each electrical connection end has an anti-extraction barb structure, which engages the printed circuit board.

In one or more embodiments, each annular metal plate is a single coil of circuit.

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.

In one or more embodiments, each annular metal plate is an annular cooper plate.

In one or more embodiments, the magnetic core has an inner chamber within which a thermal resin is filled.

In one or more embodiments, each electrical connection end has a protrusion portion that has a height.

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.

In one or more embodiments, each bobbin has a plurality of wire management slots arranged symmetrically.

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.

In one or more embodiments, the coil wires constitute three stacked layers of wires.

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.

In one or more embodiments, the magnetic component is an electric transformer.

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.

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.

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.

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.

DETAILED DESCRIPTION

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.

FIG. 1illustrates an exploded view of a magnetic component100according to one embodiment of the present disclosure. The magnetic component100includes a magnetic core102, a first winding module106and a second winding module107(also referring toFIG. 4). The magnetic core102includes two opposite openings (104a,104b) and at least one magnetic column104c. In this embodiment, the magnetic core102consists of two half magnetic cores in mirror symmetry, but not being limited to. In this embodiment, the magnetic core102may be iron oxide mixtures, such as manganese-zinc ferrite, but other metal oxide materials can also be applied on demand without limitation.

The first winding module106includes multiple annular metal plates108that are inserted through by the magnetic column104c. Each annular metal plate108includes an electrical connection end108a, an annular portion108cand a heat-dissipating end108b. The electrical connection end108aand the heat-dissipating end108bare located at (or aligned with) the two opposite openings (104a,104b) of the magnetic core102after the magnetic component is assembled. A thermal-dissipation area of the heat-dissipating end108bis greater than a cross-sectional area of a connection portion108dbetween the heat-dissipating end108band the annular portion108csuch that more thermal dissipation area can be applied with heat paste. In this embodiment, the magnetic component100can be an electric transformer, the first winding module106can be a secondary winding of the electric transformer, and the second winding module107can be a primary winding of the electric transformer.

In this embodiment, the electrical connection end108ahas a protrusion portion108ethat has a height H. The protrusion portion108eis used to inserted into a printed circuit board, and the height H may be varied to control an insulating gap between the heat-dissipating end108band a bottom surface of a concave portion126(referring toFIG. 8).

In this embodiment, each annular metal plate108can be a single coil of circuit, but the annular metal plates108can also be electrically coupled with one another to form multiple coils of circuit.

In this embodiment, each annular metal plate108can 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.

In this embodiment, a total sum of the thermal dissipation areas (at the heat-dissipating ends108b) of the first winding module106is greater than or equal to an area of the corresponding opening104bof the magnetic core102to assure a greater thermal dissipation area and the heat-dissipating end108bprotruded out of the opening104b.

Reference is made toFIG. 2andFIG. 3.FIG. 2illustrates a cross-sectional view of an annular metal plate inFIG. 1, andFIG. 3illustrates a cross-sectional view of an annular metal plate according to another embodiment of the present disclosure. As illustrated inFIG. 2, a cross-section of the heat-dissipating end108band a cross-section of the annular portion108ccollectively define an L-shaped cross-section. The L-shaped cross-section is formed by bending the heat-dissipating end108bor other mold-manufactured to enlarge the thermal dissipation area. However, the cross-section of the heat-dissipating end108band the cross-section of the annular portion108cis not limited to form an L-shape, and any shapes capable of enlarging the thermal dissipation area are applicable. For example, as illustrated inFIG. 3, a cross-section of the heat-dissipating end108b′ and a cross-section of the annular portion108cof the annular metal plate108′ collectively define a T-shaped cross-section.

In this embodiment, the heat-dissipating end108bof the annular metal plate108protrudes out of the corresponding opening104bto be in thermal contact with a heat-dissipating device, e.g., a metallic water-cooling block. The electrical connection end108aof the annular metal plate108also protrudes out of the corresponding opening104ato be electrically coupled with a printed circuit board.

Reference is made toFIG. 4andFIG. 10.FIG. 4illustrates a perspective view of a second winding module inFIG. 1.FIG. 10illustrates 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 module107includes multiple bobbins107a, and the annular metal plates108and the bobbins107aare alternately arranged within an inner chamber of the magnetic core102. The second winding module107includes multiple coil wires107bwound within a coil cavity107cof each bobbin107a. In this embodiment, the coil wires107bare three layers insulated wires (electrically-conductive wire with insulated sheath). The bobbin107ais made from electrical insulating materials such that the annular metal plates108can be electrical insulated by the bobbins107aafter they are assembled within the magnetic core102. When the magnetic component100serves as a transformer, a quantity and turns of the coil wires107band the annular metal plates108can be varied to achieve a desired voltage according to actual demands. In this embodiment, each bobbin107aalso has a plurality of wire management slots107darranged symmetrically. The coil wires107bhave their ends107b1led through corresponding ones of the wire management slots107dand electrically connected to a lead terminal150.

In this embodiment, each bobbin107ahas a convex position block107e, and the electrical connection end108ahas a notch108f, and the convex position block107eengages the notch108fwhen the bobbins107aand the annular metal plates108are assembled within the magnetic core102.

Reference is made toFIG. 5.FIG. 5illustrates an exploded view of a magnetic component according to another embodiment of the present disclosure. The magnetic component100ais different from the magnetic component100in that each coil of the magnetic component comprises two turns constituted by two annular metal plates108. In particular, two annular metal plates108are overlapped and insulated by an insulation sheet113. When each coil of the magnetic component comprises two turns constituted by two annular metal plates108, each heat-dissipating end108bhas a smaller thermal dissipation area, i.e., compared with the thermal dissipation area of the annular metal plate108inFIG. 1, the heat-dissipating ends108bare electrically insulated, e.g. by the insulation sheet113.FIG. 5only illustrates each coil of the magnetic component comprises two turns constituted by two annular metal plates108, but the coil of the magnetic component may comprise more turns constituted by the annular metal plates108.

Reference is made toFIG. 6.FIG. 6illustrates an enlarged view of the heat-dissipation end108ainFIG. 5. Each electrical connection ends of the two annular metal plates108has a barb structure110that has an anti-extraction functionality. The two barb structures110of the two annular metal plates108faces away from each other and not overlapped or aligned in position. In this embodiment, the barb structure110is formed by punching onto one surface of the annular metal plate108to form a convex portion on an opposite surface of the annular metal plate108, but the manufacturing method is not limited to this way. The barb structure110is configured to engage inside the printed circuit board to prevent from easy extraction.

Reference is made toFIG. 7.FIG. 7illustrates an assembled view of the magnetic component100ainFIG. 5. When the first winding module106and the second winding module107are alternately arranged (as illustrated inFIG. 4) and assembled, and installed into an inner chamber102aof the magnetic core102as illustrated inFIG. 7. In this embodiment, the magnetic component may have a thermal resin140filled into the inner chamber102aof the magnetic core102, so as to fill into all air gaps among the first winding module106and the second winding module107, thereby enhancing the heat-dissipating efficiency of the first winding module106and the second winding module107. After the magnetic component is assembled, the heat-dissipating end108bprotrudes out of the corresponding opening104bto be thermal contact with a heat-dissipating device, e.g., a water-cooling metal block, while the electrical connection end108aalso protrudes out of the corresponding opening104ato be coupled with a printed circuit board.

Reference is made toFIG. 8andFIG. 10.FIG. 8illustrates 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 (100aor100) are assembled, the heat-dissipating end108bis used to thermally contact a water-cooling metal block120. In this embodiment, the water-cooling metal block120has a liquid-cooling circulation passage inside thereof, and a water-cooling liquid is circulated through an inlet124aand an outlet124b. The water-cooling metal block120also has a concave portion126to accommodate the magnetic component (100aor100), and the heat-dissipating end108bof the magnetic component (100aor100) is in thermal contact with a bottom surface of the concave portion126. In another embodiment, the concave portion126may also be filled with a thermal resin, e.g., between the heat-dissipating end108band the bottom surface of the concave portion126. In this embodiment, each bobbin107aalso has a plurality of wire management slots107darranged symmetrically. The coil wires107bhave their ends107b1led through corresponding ones of the wire management slots107dand electrically connected to a lead terminal150. The lead terminal150is accommodated in another concave portion127adjacent to a side of the magnetic component (100aor100).

Reference is made toFIG. 9.FIG. 9illustrates an assembled view of an automotive power supply200according to one embodiment of the present disclosure. After the magnetic component (100aor100) is assemble to the water-cooling metal block120and other associated electronic components are installed, a printed circuit board130can be attached upon. And the electrical connection end108aof the magnetic component (100aor100) is inserted into a connection hole of the printed circuit board130, and fasteners132, e.g., screws, are used to secure the printed circuit board130to the water-cooling metal block120and the magnetic component (100aor100). The height H of the protrusion portion108emay be varied to control an insulating gap between the heat-dissipating end108band a bottom surface of the concave portion126(referring toFIG. 8).

As discussed above, the annular metal plate108of the magnetic component (100aor100) 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 end108b, 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.

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.