Abstract:
A magnetic element module includes a magnetic core assembly and at least one first winding structure. The magnetic core assembly includes a first magnetic core and a second magnetic core. The first magnetic core includes a first magnetic slab and a first magnetic post. The second magnetic core includes a second magnetic slab and a second magnetic post. The first winding structure is sheathed around the first magnetic post. The first magnetic post is placed on a second edge of the second magnetic slab. The second magnetic post is placed on a first edge of the first magnetic slab. The first magnetic core, the second magnetic core and the first winding structure are combined together, thereby producing the magnetic element module.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a magnetic element module, and more particularly to a magnetic element module having an L-shaped magnetic core assembly. 
       BACKGROUND OF THE INVENTION 
       [0002]    Nowadays, magnetic elements such as inductors and transformers are widely used in power supply apparatuses or many electronic devices to generate induced magnetic fluxes. Nowadays, the electronic device is developed toward to have small size. As such, the magnetic element and the conductive winding assembly of the magnetic element need to have slim appearance. 
         [0003]    Take an inductor for example.  FIG. 1  is a schematic exploded view illustrating a conventional inductor. As shown in  FIG. 1 , the conventional inductor  1  comprises a bobbin  11 , a magnetic core assembly  12  and a coil  13 . The bobbin  11  has a winding section  111 . The coil  13  is wound around the winding section  111 . The bobbin  11  has a channel  112  running through the bobbin. Several pins  113  are disposed on the bottom surface of the bobbin  11 . The terminals of the coil  13  are connected to the pins  113 . Via pins  113 , the coil  13  is electrically connected with a circuit board (not shown). As shown in  FIG. 1 , the magnetic core assembly  12  is an EE-type magnetic core assembly. The magnetic core assembly  12  comprises a first magnetic core  121  and a second magnetic core  122 . The first magnetic core  121  comprises a middle post  121   a  and two lateral posts  121   b . The second magnetic core  122  comprises a middle post  122   a  and two lateral posts  122   b . For assembling the inductor  1 , the middle post  121   a  of the first magnetic core  121  and the middle post  122   a  of the second magnetic core  122  are embedded into the channel  112  of the bobbin  11 , and the lateral posts  121   b  of the first magnetic core  121  are aligned with respective lateral posts  122   b  of the second magnetic core  122 . Afterward, the inductor  1  is assembled. Due to the electromagnetic induction between the coil  13 , the first magnetic core  121  and the second magnetic core  122 , an induction voltage is generated by the coil  13 . 
         [0004]    Since the bottom surfaces of the lateral posts  121   b  of the first magnetic core  121  are contacted with the bottom surfaces of respective lateral posts  122   b  of the second magnetic core  122 , misalignment between the first magnetic core  121  and the second magnetic core  122  is readily generated. In this circumstance, magnetic loss is increased, and thus the efficiency of the inductor is reduced. Moreover, since the middle post  121   a  of the first magnetic core  121  and the middle post  122   a  of the second magnetic core  122  are apart from each other by an air gap, an edge effect is generated. As the air gap between the first magnetic core  121  and the second magnetic core  122  is increased, the eddy loss is increased, the edge effect becomes more obvious, and the temperature of the inductor  1  is increased. Since the magnetic core assembly  12  is an EE-type magnetic core assembly and the coil  13  is enclosed by the lateral posts  121   b  and  122   b , the heat generated by the inductor  1  is difficult to be dissipated away. In this circumstance, the temperature of the inductor  1  is increased and a safety problem occurs. For solving this problem, an additional heat-dissipating mechanism is necessary and the fabricating cost is increased. 
         [0005]    Moreover, since the magnetic core assembly  12  is an EE-type magnetic core assembly, the winding window of the inductor  1  is restricted by the EE-type magnetic core assembly. In a case that the winding window of the magnetic element is beyond an acceptable range, the size of the magnetic core assembly  12  and the diameter, turn number or thickness of the coil  13  should be adjusted. As known, the process of changing the specification of the magnetic element is time-consuming and labor-intensive. In addition, the increase of the layout space of the magnetic element increases overall fabricating cost. 
         [0006]    Moreover, for installing two inductors  1 , the layout space and the material cost should be both doubled. In this circumstance, the layout space and the fabricating cost are increased. 
         [0007]    Therefore, there is a need of providing an improved magnetic element module to obviate the drawbacks encountered from the prior art. 
       SUMMARY OF THE INVENTION 
       [0008]    It is an object of the present invention to provide a magnetic element module for eliminating the misalignment problem in order to minimize the eddy loss, the edge effect and the temperature. 
         [0009]    Another object of the present invention provides a magnetic element module for reducing overall volume and fabricating cost. 
         [0010]    In accordance with an aspect of the present invention, there is provided a magnetic element module. The magnetic element module includes a magnetic core assembly and at least one first winding structure. The magnetic core assembly includes a first magnetic core and a second magnetic core. The first magnetic core includes a first magnetic slab and a first magnetic post. The second magnetic core includes a second magnetic slab and a second magnetic post. The first winding structure is sheathed around the first magnetic post. The first magnetic post is placed on a second edge of the second magnetic slab. The second magnetic post is placed on a first edge of the first magnetic slab. The first magnetic core, the second magnetic core and the first winding structure are combined together, thereby producing the magnetic element module. 
         [0011]    In accordance with an aspect of the present invention, there is provided a magnetic element module. The magnetic element module includes a magnetic core assembly, a first winding structure and a second winding structure. The magnetic core assembly includes a first magnetic core and a second magnetic core. The first magnetic core includes a first magnetic slab and a first magnetic post. The second magnetic core includes a second magnetic slab and a second magnetic post. The first winding structure is sheathed around the first magnetic post. The second winding structure is sheathed around the second magnetic post. The first magnetic post is placed on a second edge of the second magnetic slab. The second magnetic post is placed on a first edge of the first magnetic slab. The first magnetic core, the second magnetic core, the first winding structure and the second winding structure are combined together to produce the magnetic element module. 
         [0012]    The above contents of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a schematic exploded view illustrating a conventional inductor; 
           [0014]      FIG. 2A  is a schematic exploded view illustrating a magnetic element according to a first embodiment of the present invention; 
           [0015]      FIG. 2B  is a schematic assembled view illustrating the magnetic element as shown in  FIG. 2A ; 
           [0016]      FIG. 3A  is a schematic perspective view illustrating a magnetic element according to a second embodiment of the present invention; 
           [0017]      FIG. 3B  is a schematic assembled view illustrating the magnetic element as shown in  FIG. 3A ; 
           [0018]      FIG. 4A  is a schematic perspective view illustrating a magnetic element according to a third embodiment of the present invention; and 
           [0019]      FIG. 4B  is a schematic assembled view illustrating the magnetic element as shown in  FIG. 4A . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0020]    The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed. 
         [0021]      FIG. 2A  is a schematic exploded view illustrating a magnetic element according to a first embodiment of the present invention. As shown in  FIG. 2A , the magnetic element module  2  comprises a first winding structure  23  and a magnetic core assembly  22 . The magnetic core assembly  22  comprises a first magnetic core  221  and a second magnetic core  222 . The first magnetic core  221  comprises a first magnetic slab  221   a  and a first magnetic post  221   b . The second magnetic core  222  comprises a second magnetic slab  222   a  and a second magnetic post  222   b . For assembling the magnetic element module  2 , the first winding structure  23  is firstly sheathed around the first magnetic post  221   b , and then the first magnetic post  221   b  is placed on a second edge  222   d  of the second magnetic slab  222   a  and the second magnetic post  222   b  is placed on a first edge  221   d  of the first magnetic slab  221   a . After the first magnetic core  221 , the second magnetic core  222  and the first winding structure  23  are combined together, the magnetic element module  2  is assembled. 
         [0022]    In this embodiment, the first magnetic core  221  and the second magnetic core  222  are L-shaped magnetic cores. In some embodiments, the first magnetic slab  221   a  and the first magnetic post  221   b  of the first magnetic core  221  are integrally formed; and the second magnetic slab  222   a  and the second magnetic post  222   b  of the second magnetic core  222  are integrally formed. In some embodiments, the first magnetic slab  221   a  and the first magnetic post  221   b  are detachably connected with each other; and the second magnetic slab  222   a  and the second magnetic post  222   b  are detachably connected with each other. In some embodiments, a first recess (not shown) is formed in the first edge  221   d  of the first magnetic slab  221   a ; and a second recess  222   c  is formed in the second edge  222   d  of the second magnetic slab  222   a . The first recess and the second recess  222   c  are aligned with the second magnetic post  222   b  and the first magnetic post  221   b , respectively. 
         [0023]    In this embodiment, the magnetic element module  2  further comprises a second winding structure  21 . The first winding structure  23  and the second winding structure  21  are both flat winding coils. A process of assembling the magnetic element module  2  will be illustrated as follows. Firstly, the first magnetic post  221   b  of the first magnetic core  221  is penetrated through the channel  231  of the first winding structure  23 , and the second magnetic post  222   b  of the second magnetic core  222  is penetrated through the channel  211  of the second winding structure  21 , so that the first winding structure  23  and the second winding structure  21  are respectively sheathed around the first magnetic post  221   b  and the second magnetic post  222   b . Then, the tips of the first magnetic post  221   b  and the second magnetic post  222   b  are respectively accommodated within the second recess  222   c  of the second magnetic slab  222   a  and the first recess of the first magnetic slab  221   a . After the first magnetic core  221 , the second magnetic core  222 , the first winding structure  23  and the second winding structure  21  are combined together, the magnetic element module  2  is assembled (see  FIG. 2B ). 
         [0024]    In some embodiments, for facilitating connecting the first magnetic core  221  and the second magnetic core  222 , some solder paste may be applied to the junction between the first magnetic post  221   b  and the second recess  222   c  and the junction between the second magnetic post  222   b  and the first recess. 
         [0025]    Please refer to  FIG. 2B  again. The magnetic element module  2  comprises two winding structures. Since the first winding structure  23  and the second winding structure  21  are respectively sheathed around the first magnetic post  221   b  and the second magnetic post  222   b , electromagnetic induction between the first winding structure  23 , the second winding structure  21  and the magnetic core assembly  22  will be generated. In other words, the magnetic element module  2  is composed of two inductors  24  and  25 , which are connected in parallel. Since the two inductors  24  and  25  collectively utilize a single magnetic core assembly  22 , the overall volume of the magnetic element module  2  is reduced and the fabricating cost is reduced. Moreover, since the first magnetic core  221  and the second magnetic core  222  of the magnetic core assembly  22  have the same profiles, the first magnetic core  221  and the second magnetic core  222  may be produced in the same mold in order to further reduce the fabricating cost. 
         [0026]      FIG. 3A  is a schematic perspective view illustrating a magnetic element according to a second embodiment of the present invention.  FIG. 3B  is a schematic assembled view illustrating the magnetic element as shown in  FIG. 3A . In this embodiment, the magnetic element module  3  comprises a first winding structure  31 , a second winding structure  33  and a magnetic core assembly  32 . The configurations of the magnetic core assembly  32  are similar to those of the magnetic core assembly  22 , and are not redundantly described herein. In this embodiment, the first winding structure  31  and the second winding structure  33  comprise a first bobbin  311  and a second bobbin  331 , respectively. The coils  34  and  35  are respectively wound around the first bobbin  311  and a second bobbin  331 . In this embodiment, the coils  34  and  35  are flat winding coils, copper slices, or the like. 
         [0027]    A process of assembling the magnetic element module  3  will be illustrated as follows. Firstly, the first magnetic post  321   b  of the first magnetic core  321  is penetrated through the channel  312  of the first bobbin  311  of the first winding structure  31 , and the second magnetic post  322   b  of the second magnetic core  322  is penetrated through the channel  332  of the second winding structure  33 , so that the first winding structure  31  and the second winding structure  33  are respectively sheathed around the first magnetic post  321   b  and the second magnetic post  322   b . Then, the tips of the first magnetic post  321   b  and the second magnetic post  322   b  are respectively accommodated within the second recess  322   c  of the second magnetic slab  322   a  and the first recess (not shown) of the first magnetic slab  321   a . After the first magnetic core  321 , the second magnetic core  322 , the first winding structure  31  and the second winding structure  33  are combined together, the magnetic element module  3  is assembled (see  FIG. 3B ). As shown in  FIG. 3B , the magnetic element module  3  is composed of two transformers  36  and  37 , which are connected in parallel. Since the two transformers  36  and  37  collectively utilize a single magnetic core assembly  32 , the overall volume of the magnetic element module  3  is reduced and the fabricating cost is reduced. 
         [0028]      FIG. 4A  is a schematic perspective view illustrating a magnetic element according to a third embodiment of the present invention.  FIG. 4B  is a schematic assembled view illustrating the magnetic element as shown in  FIG. 4A . In this embodiment, the magnetic element module  4  comprises a first winding structure  43 , a second winding structure  41  and a magnetic core assembly  42 . The magnetic core assembly  42  comprises a first magnetic core  421  and a second magnetic core  422 . The first magnetic core  421  comprises a first magnetic slab  421   a , a first magnetic post  421   b  and a first recess (not shown). The second magnetic core  422  comprises a second magnetic slab  422   a , a second magnetic post  422   b  and a second recess  422   c . Similarly, the first magnetic core  421  and the second magnetic core  422  of the magnetic core assembly  42  are L-shaped magnetic cores. The configurations of the magnetic core assembly  42  are similar to those of the magnetic core assembly  22  or  32 , and are not redundantly described herein. The second winding structure  41  further comprises a second bobbin  411 , and a coil  44  is wound around the second bobbin  411 . That is, the second winding structure  41  is a winding coil assembly. In addition, the first winding structure  43  is a flat winding coil. 
         [0029]    A process of assembling the magnetic element module  4  will be illustrated as follows. Firstly, the first magnetic post  421   b  of the first magnetic core  421  is penetrated through the channel  431  of the first winding structure  43 , and the second magnetic post  422   b  of the second magnetic core  422  is penetrated through the channel  412  of the second winding structure  41 , so that the first winding structure  43  and the second winding structure  41  are respectively sheathed around the first magnetic post  421   b  and the second magnetic post  422   b . Then, the tips of the first magnetic post  421   b  and the second magnetic post  422   b  are respectively accommodated within the second recess  422   c  of the second magnetic slab  422   a  and the first recess (not shown) of the first magnetic slab  421   a . After the first magnetic core  421 , the second magnetic core  422 , the first winding structure  43  and the second winding structure  41  are combined together, the magnetic element module  4  is assembled (see  FIG. 4B ). As shown in  FIG. 4B , the magnetic element module  4  is composed of an inductor  45  and a transformer  46 . Since the inductor  45  and the transformer  46  collectively utilize a single magnetic core assembly  42 , the overall volume of the magnetic element module  4  is reduced. 
         [0030]    In the above embodiments, the magnetic element module may be a combination of two inductors, a combination of two inductors, or a combination of an inductor and a transformer. As a consequence, the flexibility and diversity of the magnetic element module are enhanced. 
         [0031]    As previously described, the applications of the EE-type magnetic core assembly are restricted by the lateral posts. Whereas, according to the present invention, the positions of the first magnetic post  421   b  and the second magnetic post  422   b  of the magnetic core assembly  42  may be fine-tuned in order to comply with the practical requirements. Since the junction between the first magnetic post  421   b  and the second recess  422   c  is located in the second magnetic slab  422   a  and the junction between the second magnetic post  422   b  and the first recess is in the first magnetic slab  421   a , the eddy loss is reduced. Moreover, since the first winding structure  43  and the second winding structure  41  are no longer enclosed by the magnetic core assembly  42 , the heat generated by the magnetic element module  4  could be effectively radiated to the air. As a consequence, the heat-dissipating efficacy is enhanced and the temperature is reduced. 
         [0032]    From the above description, the magnetic element module of the present invention includes a first winding structure, a second winding structure and an L-shaped magnetic core assembly. The magnetic core assembly comprises a first magnetic core and a second magnetic core. The first magnetic core comprises a first magnetic slab and a first magnetic post. The second magnetic core comprises a second magnetic slab and a second magnetic post. The first magnetic post and the second magnetic post are respectively penetrated through the channels of the first winding structure and the second winding structure. After the first magnetic core, the second magnetic core, the first winding structure and the second winding structure are combined together, the magnetic element module is assembled. In other words, the magnetic element module of the present invention is composed of two magnetic elements, which are connected in parallel. Since the two magnetic elements collectively utilize a single magnetic core assembly, the flexibility and diversity of the magnetic element module are enhanced, the overall volume of the magnetic element module is reduced and the fabricating cost is reduced. Moreover, since the junctions between the first magnetic core and the second magnetic core are located in the first magnetic slab and the second magnetic slab, the eddy loss and the temperature are reduced. Since the two magnetic elements collectively utilize a single magnetic core assembly, the fabricating process is simplified, the misalignment problem is minimized, and the overall volume is reduced. 
         [0033]    While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.