Patent Publication Number: US-2019198220-A1

Title: Magnetic component

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This non-provisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 201711431995.7 filed in P.R. China on Dec. 26, 2017, the entire contents of which are hereby incorporated by reference. 
     Some references, if any, which may include patents, patent applications and various publications, may be cited and discussed in the description of this invention. The citation and/or discussion of such references, if any, is provided merely to clarify the description of the present invention and is not an admission that any such reference is “prior art” to the invention described herein. All references listed, cited and/or discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Application 
     The present application relates to a magnetic component, and specifically, relates to a magnetic component which is capable of improving a fixing strength of the winding. 
     2. Related Art 
     With an increasing of demand for a power density of the magnetic component, the challenge to technicians is higher. Currently, most of the magnetic components are formed of a magnetic core, a winding and a bobbin. However, the bobbin for winding cannot improve the electrical performance while occupying about 30% of volume of a winding space in the magnetic component, so the technicians are considering omitting the bobbin of the magnetic component. 
     In the existing magnetic component without bobbin, the winding is often fixed by tapes on four sides. However, such fixing method is complicated in operation and low in efficiency, and may easily lead to collapse of winding formation, looseness of winding and the like, such that the potential problem in quality of the magnetic component may exist. Therefore, there is an urgent requirement to develop a winding structure for overcoming the above defects. 
     SUMMARY OF THE INVENTION 
     In order to overcome the existing problems in the prior art, an object of the present application is to provide a magnetic component, comprising: a magnetic core comprising at least one core column; a winding winded on the core column and comprising a first coil and a second coil adjacent to the first coil; a cladding member covered on at least a portion of an external surface of the first coil; and a positioning member extending from the cladding member and the first coil, wherein the second coil is pressed on the positioning member. 
     As compared to the prior art, the present application may have the following advantage. 
     The cladding member and the positioning member extending from the cladding member are disposed on the external surface of the coil, and the positioning member is pressed by at least one turn of another coil, so as to improve the fixing strength of the winding and reduce the potential problem in quality. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a structure diagram of a first embodiment of a cladding member in the present application. 
         FIG. 2  is a structure diagram of a first embodiment of a magnetic component in the present application. 
         FIG. 3  is a structure diagram of a second embodiment of a magnetic component in the present application. 
         FIG. 4  is a structure diagram of a third embodiment of a magnetic component in the present application. 
         FIG. 5  is a structure diagram of a second embodiment of a cladding member in the present application. 
         FIG. 6  is a structure diagram of a third embodiment of a cladding member in the present application. 
         FIG. 7  is a structure diagram of a fourth embodiment of a cladding member in the present application. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present application will be described in detail with reference to the drawings and the specific embodiments, which are implemented on the premise of the technical solution of the present application to interpret the implementing manner and the operating process. However, the protection scope of the present application is not limited to the specific embodiments. 
     Please refer to  FIGS. 1 and 2 .  FIG. 1  is a structure diagram of a first embodiment of a cladding member in the present application, and  FIG. 2  is structure diagram of a first embodiment of a magnetic component in the present application. As shown in  FIGS. 1 and 2 , the magnetic component comprises a magnetic core comprising at least one core column  11 ; a winding  12  winded on the core column  11  and comprising a first coil  121  and a second coil  122  adjacent to the first coil  121 ; a cladding member  13  covered on at least a portion of an external surface of the first coil  121 ; and a positioning member  14  extending from the cladding member  13  and the first coil  121 . The positioning member  14  is pressed by the second coil  122  to improve the fixing strength of the winding and reduce the potential problem in quality. Further, the positioning member  14  of the first coil  121  may have adhesiveness to be pressed more tightly by the second coil  122 . 
     In this embodiment, the winding  12  may be a multi-layered winding. However, the present application is not limited thereto. In other embodiment, the winding  12  may be a single-layered winding. Moreover, the present application will not limit the number of the first coil  121 . The winding  12  may include multiple groups of the first coil  121 , the cladding member  13  and the positioning member  14 , and the first coil  121  may be any turn of the winding  12 . Preferably, as shown in  FIG. 2 , as for a coil on a certain layer of the winding  12 , only a portion of the coil may be configured as the first coil  121 , such that the coil space occupied by the cladding member  13  and the positioning member  14  can be minimized while improving the fixing strength of the winding, so as to ensure the power density of the magnetic component. 
     Explanations will be made in detail by taking  FIG. 2  for example. In one embodiment of the present application, if the winding  12  is winded in a direction from left to right, and an inner layer to an outer layer of the magnetic component are arranged in a direction from bottom to top, the positioning member  14  of the first coil  121  on the leftmost is at least pressed by the second coil  122  adjacent to the first coil  121  on the right side, i.e., pressed by the coil on the same layer, and the positioning member  14  of the first coil  121  on the rightmost is at least pressed by the second coil  122  adjacent to the first coil  121  on the upper layer. In other words, the first coil  121  and the second coil  122  may be on a same layer or different layers of the winding  12 . The actual winding may be correspondingly adjusted according to the winding manner of the magnetic component, only if the positioning member  14  of the first coil  121  is pressed by any turn of the second coil  122  adjacent to the first coil  121 . Moreover, the second coil  122  may also be provided with the cladding member  13  and the positioning member  14 . 
     Further, in order to improve the insulating performance of the magnetic component, the cladding member  13  and the positioning member  14  of the present application may be made of insulating material, and at least one of the number of layers of the cladding member  13 , the position of the cladding member  13  and the length of the positioning member  14  can be adjusted according to safety requirements. For example, the magnetic component may comprise an insulating tape, the winding  12  is prepared by winding a conducting wire, and the insulating tape is adhered to at least a portion of the conducting wire by pinching. When the conducting wire is winded on the magnetic core, the adhered insulating tape may form the cladding member  13  as shown in  FIG. 1 . Moreover, the insulating tape forming the positioning member  14  may not be completely aligned, and a portion of the adhesive surface (a surface with adhesive layer) of the insulating tape is exposed, such that the positioning member  14  may have adhesiveness to be pressed more tightly by the second coil  122 . During the actual winding process, a position of the first coil  122  on the winding  12 , i.e., a position of the cladding member  13 , can be controlled conveniently by adjusting a position of the insulating tape adhered on the conducting wire. For example, when the magnetic component is a transformer winded by sequentially stacking a primary side and a secondary side, at least one turn of coil at each end of a secondary winding and/or a primary winding may be covered with the insulating tape to improve the insulating performance of the magnetic component. 
     Please refer to  FIG. 3 .  FIG. 3  is a structure diagram of a second embodiment of a magnetic component in the present application. As compared to the first embodiment of the magnetic component as shown in  FIG. 2 , the magnetic component in the second embodiment further comprises an interlayer tape  15  disposed between adjacent two layers of the winding  12 , wherein the positioning member  14  is pressed by both of the interlayer tape  15  and the second coil  12  to further improve the fixing strength of the winding. Explanations will be made by taking  FIG. 3  for example. If the winding  12  is winded in a direction from left to right, and an inner layer to an outer layer of the magnetic component are arranged in a direction from bottom to top, at least the adjacent second coil  122  on the right side and the interlayer tape  15  on the upper side are both pressed on the positioning member  14  of the first coil  121  on the leftmost, and at least the adjacent second coil  122  on the upper side and the interlayer tape  15  on the upper side are both pressed on the positioning member  14  of the first coil  121  on the rightmost. Further, the magnetic component may comprise an outer tape  17  pressed on an outermost layer of the winding  12  to further improve the fixing strength of the winding. On the other hand, in order to improve the insulating performance of the magnetic component, the interlayer tape  15  and/or the outer tape  17  may be made of insulating material. 
     Please refer to  FIG. 4 .  FIG. 4  is a structure diagram of a third embodiment of a magnetic component in the present application. The fixing structure of the present application may also be applied to a magnetic component including a bobbin. As shown in  FIG. 4 , the winding  12  is winded on the magnetic core  11  through a bobbin  16 , i.e., the bobbin  16  is disposed between the winding  12  and the magnetic core  11 . 
     It is to be noted that the structures of the cladding member and the positioning member in  FIGS. 1 to 4  are only exemplary examples, and other structure may be formed by varying the fabricating method. 
     Please refer to  FIG. 5 .  FIG. 5  is a structure diagram of a second embodiment of a cladding member in the present application, and differs from  FIG. 1  in that the cladding member  13  in  FIG. 5  has a multilayer structure and a multi-layered cladding member  13  is covered on an external surface of the first coil  121  by pinching. Explanations will be made by taking the insulating tape for example. The winding  12  is prepared by winding a conducting wire, and a pre-prepared multi-layered insulating tape is pinched on at least a portion of the conducting wire. When the conducting wire is winded on the magnetic core, the adhered insulating tape may form the multi-layered cladding member as shown in  FIG. 5 . 
     Please refer to  FIG. 6 .  FIG. 6  is a structure diagram of a third embodiment of a cladding member in the present application, and differs from  FIG. 5  in that the multi-layered cladding member  13  is covered on an external surface of the first coil  121  by winding. Explanations will be made by taking the insulating tape for example. The winding  12  is prepared by winding a conducting wire, and the insulating tape is adhered to at least a portion of the conducting wire by winding several times. When the conducting wire is winded on the magnetic core, the adhered insulating tape may form the multi-layered cladding member as shown in  FIG. 6 . 
     It is to be noted that the structures of the cladding member in  FIGS. 1, 5 and 6  are enclosed structures. However, the present application is not limited thereto. As shown in  FIG. 7 , the cladding member  13  may be only covered on a portion of an external surface of the first coil  121 . The present application will not limit the specific structures of the cladding member and the positioning member, only if the positioning member  14  is pressed by the second coil. Moreover, the structures of the cladding member and the positioning member in  FIGS. 5 to 7  may also be applied to the magnetic components in  FIGS. 2 to 4 , and the detailed explanation will be omitted. 
     In conclusion, the fixing strength of the winding can be improved through the winding structure of the present application, such that the reliability of the magnetic component, especially the reliability of the magnetic component without bobbin, may be improved. Further, when the cladding member and the positioning member are made of insulating material, an insulating performance between the coils can be improved, and safety requirement can be satisfied by adjusting at least one of the number of layers of the cladding member  13 , the position of the cladding member  13  and the length of the positioning member  14 , so as to improve safety assurance. 
     It is to be noted that, the specific embodiments are merely provided to explain the present application, instead of limiting the technical solution of the present application. Meanwhile, although the Description explains the present application in detail with reference to the specific embodiments, those having ordinary knowledge in the technical field shall understand that modifications or equivalent replacements may be made to the present application. Therefore, any technical solution and its modification without departing from the spirit and scope of the present application shall be contained within the protection scope of the appended claims of the present application.