Magnetic components and methods of manufacturing the same

The field of the present invention generally relates to magnetic components and their manufacture, and more specifically to magnetic surface mount electronic components such as inductors and transformers.

Advances in electronic packaging have made it possible to manufacture smaller and more powerful electronic devices. In order to reduce the overall size of these devices, the electronic components used to manufacture these devices are becoming smaller and smaller. Manufacturing electronic components to meet these requirements presents many difficulties, thus making the manufacturing process more costly and undesirably increasing the cost of electronic components.

Manufacturing processes for magnetic components such as inductors and transformers, like other components, have been scrutinized as a way to reduce costs in the highly competitive electronic component manufacturing business. Reduction of manufacturing cost is especially desirable when the parts to be manufactured are low cost and high volume parts. Not surprisingly, any reduction in manufacturing costs is important in high volume mass production processes for these components and the electronic devices that use them.

Allows for the following advantages: component structures that are easier to produce at the miniaturization level, component structures that are more easily assembled at the miniaturization level, and elimination of manufacturing steps common to known magnetic component configurations. A component structure, a component structure with improved reliability due to more effective manufacturing techniques, and a component structure with similar or reduced package size and improved performance compared to existing magnetic components. A component with a component structure that has increased power performance compared to traditional miniaturized magnetic components and a unique core and coil configuration that offers distinct performance advantages over known magnetic component configurations. Illustrative embodiments of magnetic component assemblies and methods of manufacturing assemblies that are advantageously used to realize one or more of the structural advantages are disclosed herein.

This exemplary component assembly is considered to be particularly advantageous for constructing, for example, inductors and transformers. This assembly will be offered reliably in a small package size and will include surface mount features for ease of mounting on circuit boards.

Non-limiting and non-exclusive embodiments are described with reference to the following drawings, wherein similar reference numbers refer to similar parts in all of the various drawings unless otherwise indicated.

<figref num="1">FIG. 1 shows a perspective view and an exploded view of the upper side of a small power inductor according to an exemplary embodiment of the present invention.</figref><figref num="2">FIG. 2 shows an upper perspective view of the small power inductor shown in FIG. 1 in an intermediate manufacturing step according to an exemplary embodiment.</figref><figref num="3">FIG. 3 shows a perspective view of the lower side of the small power inductor shown in FIG. 1 according to an exemplary embodiment.</figref><figref num="4">FIG. 4 shows a perspective view of an exemplary winding shape configuration for the small power inductors shown in FIGS. 1, 2 and 3 according to an exemplary embodiment.</figref><figref num="5">FIG. 5 shows the shape configuration of the coil according to the embodiment of the present invention.</figref><figref num="6">FIG. 6 shows a cross-sectional view of a magnetic component including the coil configuration shown in FIG.</figref><figref num="7">FIG. 7 is a schematic plan view of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="8">FIG. 8 is a schematic plan view of another magnetic component including the coupling coil.</figref><figref num="9">FIG. 9 is a cross-sectional view of the component assembly shown in FIG.</figref><figref num="10">FIG. 10 is a schematic plan view of another magnetic component assembly that includes a coupling coil.</figref><figref num="11">FIG. 11 is a cross-sectional view of the component shown in FIG.</figref><figref num="12">FIG. 12 is a schematic plan view of another embodiment of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="13">FIG. 13 is a cross-sectional view of the component shown in FIG.</figref><figref num="14">FIG. 14 is a perspective view of another embodiment of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="15">FIG. 15 is a schematic plan view of the parts shown in FIG.</figref><figref num="16">FIG. 16 is an upper perspective view of the component shown in FIG.</figref><figref num="17">FIG. 17 is a lower perspective view of the component shown in FIG.</figref><figref num="18">FIG. 18 is a perspective view of another embodiment of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="19">FIG. 19 is a schematic plan view of the parts shown in FIG.</figref><figref num="20">FIG. 20 is a lower perspective view of the component shown in FIG.</figref><figref num="21">FIG. 21 is a perspective view of another embodiment of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="22">FIG. 22 is a schematic plan view of the parts shown in FIG.</figref><figref num="23">FIG. 23 is a perspective view of the lower part of the component shown in FIG.</figref><figref num="24">FIG. 24 is a perspective view of another embodiment of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="25">FIG. 25 is a schematic plan view of the parts shown in FIG. 24.</figref><figref num="26">FIG. 26 is a perspective view of the lower part of the component shown in FIG. 24.</figref><figref num="27">FIG. 27 shows the results of simulation and testing of a magnetic component, including a coupling coil, according to an exemplary embodiment of the invention, for a component with discrete core pieces that are physically gapped.</figref><figref num="28">FIG. 28 shows yet another analysis of a magnetic component including a coupling coil according to an exemplary embodiment of the invention.</figref><figref num="29">FIG. 29 shows simulation data of a magnetic component including a coupling coil according to an exemplary embodiment of the invention for a component with discrete core pieces that are physically gapped.</figref><figref num="30">FIG. 30 shows yet another analysis of a magnetic component including a coupling coil according to an exemplary embodiment of the invention.</figref><figref num="31">FIG. 31 shows yet another analysis of a magnetic component including a coupling coil according to an exemplary embodiment of the invention.</figref><figref num="32">FIG. 32 shows the results of simulation and testing of a magnetic component including a coupling coil according to an exemplary embodiment of the present invention.</figref><figref num="33">FIG. 33 shows the binding results obtained from the information in FIGS. 27-31.</figref><figref num="34">FIG. 34 shows an embodiment of a magnetic component assembly and a circuit board for the magnetic component assembly.</figref><figref num="35">FIG. 35 shows another magnetic component assembly with a coupling coil.</figref><figref num="36">FIG. 36 is a cross-sectional view of the assembly shown in FIG.</figref><figref num="37">FIG. 37 shows a comparison of the ripple currents of embodiments of the present invention with coupling coils for discrete magnetic components without coupling coils.</figref><figref num="38">FIG. 38 is a perspective view of another embodiment of the magnetic component.</figref><figref num="39">FIG. 39 is a plan view of the component shown in FIG. 38.</figref><figref num="40">FIG. 40 is a bottom view of the component shown in FIG. 38.</figref><figref num="41">FIG. 41 is a perspective view of another magnetic component.</figref><figref num="42">FIG. 42 is a side view of the component shown in FIG. 41.</figref><figref num="43">FIG. 43 is a side view of another embodiment of the component shown in FIG. 41 from which the coil has been removed.</figref><figref num="44">FIG. 44 is a side view of another embodiment of the component shown in FIG. 43.</figref><figref num="45">FIG. 45 is a side view of another embodiment of the component shown in FIG.</figref>

An exemplary embodiment of the electronic component design of the present invention that overcomes a number of difficulties in the art is described herein. To fully understand the invention, the following disclosures are presented in the form of different segments or parts, where Part I refers to specific problems and difficulties, and Part II refers to these problems. An exemplary component configuration and assembly for overcoming the points will be described.

I. Introduction to the present invention

Traditional magnetic components, such as inductors for circuit board applications, typically include a magnetic core and conductive windings, sometimes also referred to as coils within the magnetic core. This core would be made from discrete core pieces made of magnetic material with windings placed between the core pieces. Core pieces and assemblies of various shapes and types, including but not limited to U-core and I-core assemblies, ER-core and I-core assemblies, ER-core and ER-core assemblies, pot-core and T-core assemblies, and other compatible shapes. Is well known to those skilled in the art. The discrete core pieces are glued together and typically are physically separated or gapped from each other.

In some known parts, for example, the coil is a core or terminal clip. It is made from conductive wire that is wrapped around a clip). That is, the wire will be wrapped around this core piece after the core piece, sometimes referred to as the drum core or bobbin core, has been completely formed. Because each free end of the coil is called a lead and couples the inductor to the electrical circuit through direct mounting to the circuit board or through indirect connections via terminal clips. Will be used for. Especially in the case of a small core piece, it is difficult to wind the coil in a cost-effective and reliable manner. Hand-wound parts tend to have inconsistent performance. The core pieces are very fragile due to their shape, are likely to crack the core when the coil is wound, and fluctuations in the gaps between the core pieces cause unwanted changes in component performance. There is a possibility of causing it. Yet another difficulty is that the DC resistance (DCR) can change in an undesired way due to uneven winding and pulling during the winding process.

In other known components, coils for known surface mount magnetic components are typically manufactured separately from the core piece and later assembled with the core piece. Sand Wachi, in order to avoid problems due to the winding of the manual coil, and, in order to simplify the magnetic component of the assembly, the coil may be referred to as preformed coils or pre-wound coils .. This preformed coil is particularly advantageous for small component sizes.

Conductive terminals or clips are typically provided to make electrical connections to the coil when the magnetic component is surface mounted on a circuit board. The clip is assembled on a molded core piece and electrically connected to each end of the coil. The terminal clips typically include a generally flat, planar area that can be electrically connected to conductive traces and pads on the circuit board, eg, using known soldering methods. When connected in this way, and when current is supplied to the circuit board, current flows from the circuit board to one terminal clip, through the coil, to the other terminal clip, and to the circuit board. Will come back. In the case of inductors, the current passing through the coil creates a magnetic field and energy in the magnetic core. Two or more coils may be provided.

In the case of a transformer, a primary coil and a secondary coil are provided, and the current passing through the primary coil induces the current in the secondary coil. Manufacture of transformer components presents similar difficulties to inductor components.

As components become smaller and smaller, providing physically gapped cores is a difficult problem. Ensuring and maintaining a uniform gap size is difficult to reliably achieve in a cost-effective manner.

In addition, there are some practical problems with creating electrical connections between coils and terminal clips in miniaturized surface mount magnetic components. Typically, a very fragile connection between the coil and the terminal clip is made outside the core, which makes it easy to separate. In some cases, it is known to wrap the end of the coil around a portion of the terminal clip to ensure a reliable mechanical and electrical connection between the coil and the terminal clip. ing. However, this has proven to be time consuming from a manufacturing standpoint, and an easier and faster termination solution would be desirable. In addition to this, in the case of some types of coils, such as coils with a rectangular cross section that have a flat surface that is not as flexible as a thin, round wire configuration, winding the coil ends is not practical. Absent.

As electronic devices continue the recent trend of becoming more and more powerful, magnetic components such as inductors are required to carry an ever-increasing amount of current. As a result, the gauge of the wire used to make the coil is typically increased. Due to the increased size of the wire used to make the coil, when a round wire is used to make the coil, its ends are typically, for example, soldered, welded, or conductive. It is flattened to a suitable thickness and width so that mechanical and electrical connections to the terminal clips can be properly achieved using adhesives or the like. However, the larger the gauge of the wire, the more difficult it becomes to flatten the end of the coil in order to properly connect the end of the coil to the terminal clip. These problems result in a non-uniform connection between the coil and the terminal clip that can cause unwanted performance problems and variations in the magnetic component during use. Reducing these fluctuations has already proved to be very difficult and costly.

Manufacture of coils from non-round flat conductors would alleviate these problems for certain applications, but flat conductors are stiffer, less bendable, and can be formed in the shape of a coil in the first place. It is more difficult and therefore tends to cause other manufacturing problems. The use of non-round, flat conductors can also change the performance of the part in use, sometimes in unwanted shapes. In addition to this, in some known configurations, especially those that include coils made from flat conductors, termination feature elements such as hooks or other structural feature elements connect to the terminal clips. May be formed in the shape of the end of the coil to facilitate. However, forming these feature elements in the shape of the end of the coil can add additional costs to the manufacturing process.

Recent trends in shrinking size further increase the power and capacity of electronic devices, creating yet another challenge. As the size of the electronic device is reduced, the size of the electronic components used within the electronic device must be reduced, thus carrying an increased amount of current to power the electronic device. Rather, efforts have been made to economically manufacture power inductors and transformers that are relatively small and sometimes have a miniaturized configuration. It is desirable for the magnetic core structure to have an increasingly lower profile relative to the circuit board in order to achieve a thin (and sometimes very thin) profile of the electrical device. Meeting these requirements poses yet another challenge. Yet another conundrum arises with respect to the components connected to the multiphase power system, where it is difficult for miniaturized devices to adapt to different phases of power.

Efforts to optimize the footprint and profile of magnetic components are of great importance to component manufacturers seeking to meet the dimensional requirements of modern electronic devices. Each component on a circuit board is a component on a circuit board that is measured by the dimensions of the vertical width and depth measured in a plane parallel to the circuit board, that is, sometimes referred to as the "footprint" of the component. Will generally be defined by the product of width and depth, which determines the surface area occupied by. On the other hand, the total height of a component measured in a direction perpendicular to or perpendicular to the circuit board is sometimes referred to as the "profile" of the component. The component footprint determines in part how many components can be mounted on the circuit board, and the profile is partially realized between the circuit boards parallel to each other in the electronic device. Determine the interval. Smaller electronic devices generally require more components to be mounted on each existing circuit board, or the gap between adjacent circuit boards to be reduced, or both.

However, many known terminal clips used with magnetic components tend to increase the footprint and / or profile of the magnetic component when it is surface mounted on a circuit board. That is, these terminal clips tend to increase the depth, width and / or height of the magnetic component as it is mounted on the circuit board, and undesirably increase the footprint and / or profile of the magnetic component. is there. Especially in the case of clips that are attached over the entire outer surface of the magnetic core piece at the top or bottom or sides of the magnetic core, the footprint and / or profile of the finished part is magnified by the terminal clip. Let's do it. Even when the component profile or height expansion is relatively small, the effect can be significant as the number of components and circuit boards increases in any particular electronic device.

II. Example and original method of assembling and manufacturing magnetic parts

Hereinafter, exemplary embodiments of magnetic component assemblies that address some of the problems of conventional magnetic components in the art will be described. For illustration purposes, exemplary embodiments of magnetic component assemblies and manufacturing methods are collectively described with respect to common design features that address specific problems in the art.

The manufacturing steps associated with the devices described above are partially obvious and, in part, specifically described below. Similarly, the devices associated with the method steps described are partially obvious and, in part, specifically described below. That is, the devices and methods of the present invention do not necessarily have to be described separately in the description below, but are considered to be well within the understanding of those skilled in the art without further description.

With reference to FIGS. 1 to 4, some drawings of exemplary embodiments of the magnetic component or device 100 are shown. FIG. 1 is a small power inductor with a 3-turn clip winding in an exemplary winding structure, at least one magnetic powder sheet, and a horizontally oriented core area according to an exemplary embodiment. The perspective view and the exploded view of the upper side of the above are shown. FIG. 2 shows a perspective view of the upper side of the small power inductor shown in FIG. 1 during an intermediate manufacturing stage according to an exemplary embodiment. FIG. 3 shows a perspective view of the lower side of the small power inductor shown in FIG. 1 according to an exemplary embodiment. FIG. 4 shows a perspective view of the eleventh winding structure of the small power inductor shown in FIGS. 1, 2 and 3 according to an exemplary embodiment.

In this embodiment, the small power inductor 100 is coupled to at least one magnetic powder sheet 101, 102, 104, 106 and at least one magnetic powder sheet 101, 102, 104, 106 in the winding structure 114. Each comprises a magnetic material comprising a plurality of coils or windings 108, 110, 112, which may be in the form of clips. As can be understood from this embodiment, the small power inductor 100 is located on a first magnetic powder sheet 101 having a lower surface 116 and an upper surface located on the opposite side of the lower surface, and on the lower surface opposite to the lower surface. It includes a second magnetic powder sheet 102 having an upper surface 118, a third magnetic powder sheet 104 having a lower surface 120 and an upper surface 122, and a fourth magnetic powder sheet 106 having a lower surface 124 and an upper surface 126. ..

Magnetic layers 101, 102, 104, 106 are of relatively thin sheets that are stacked with coils or windings 108, 110, 112 and joined to each other by laminating methods or other methods known in the art. It is provided in shape. The magnetic layers 101, 102, 104, 106 may be prefabricated in separate manufacturing steps to facilitate the formation of magnetic components in subsequent assembly steps. It is advantageous that the magnetic material can be molded into the desired shape, for example by compression molding or other methods, such as binding the magnetic layer to the coil and defining the magnetic material into the desired shape. The ability to form a magnetic material means that a magnetic material can be formed around the coils 108, 110, 112 in the form of an integral or monolithic structure containing the coils, and one. Alternatively, it is advantageous in that separate manufacturing steps of assembling multiple coils into a magnetic structure are avoided. Magnetic materials of various shapes will be provided in various embodiments.

In an exemplary embodiment, each magnetic powder sheet may be, for example, a magnetic powder sheet manufactured by Chang Sung Incorporated (Incheon, Korea) and sold as part number 20u-eff Flexible Magnetic Sheet. In addition, these magnetic powder sheets have particles that are predominantly oriented in a particular direction. Therefore, higher inductance will be achieved when a magnetic field is generated in the direction of the predominant magnetic particle orientation. Although this embodiment shows four magnetic powder sheets, the number of magnetic sheets may be increased or decreased to increase or decrease the core area without departing from the scope and ideas of this exemplary embodiment. Further, although this embodiment shows a magnetic powder sheet, any flexible sheet that can be laminated without departing from the scope and ideas of this exemplary embodiment is used as an alternative. There is.

In yet another and / or alternative embodiment, the magnetic sheet or magnetic layer 101, 102, 104, 106 may be made from the same type of magnetic particles or different types of magnetic particles. That is, in one embodiment, all of the magnetic layers 101, 102, 104, 106 are the same so that the magnetic layers 101, 102, 104, 106 have substantially similar (if not identical) magnetic properties. It may be manufactured from one type of magnetic particle. However, in another embodiment, one or more of the magnetic layers 101, 102, 104, 106 can be made from different types of magnetic powder particles than the other layers. For example, the inner magnetic layers 104 and 106 are of a different type from the outer magnetic layers 101 and 106 so that the inner magnetic layers 104 and 106 have different properties than the outer magnetic layers 101 and 106. It may contain magnetic particles. Therefore, the performance characteristics of the finished component will vary depending on the number of magnetic layers used and the type of magnetic material used to form each of the magnetic layers.

In this embodiment, the third magnetic powder sheet 104 has a first indentation 128 on the lower surface 120 of the third magnetic powder sheet 104 and a first on the upper surface 122 of the third magnetic powder sheet 104. Will include an extraction 130, in which case the first recess 128 and the first protrusion 130 will have one edge substantially along the center of the third magnetic powder sheet 104. Extends from to the edge located on the opposite side. The first recess 128 and the first protrusion 130 include a plurality of the first recess 128 and the first protrusion 130 when the third magnetic powder sheet 104 is coupled to the second magnetic powder sheet 102. It is oriented so that it extends in the same direction as the windings 108, 110, 112. The first recess 128 is designed to enclose a plurality of windings 108, 110, 112.

In this embodiment, the fourth magnetic powder sheet 106 has a second recess 132 on the lower surface 124 of the fourth magnetic powder sheet 106 and a second protrusion on the upper surface 126 of the fourth magnetic powder sheet 106. It will include 134, in which case the second recess 132 and the second protrusion 134 are located substantially along the center of the fourth magnetic powder sheet 106, opposite from one edge. Extends to the edge. The second recess 132 and the second protrusion 134 are such that when the fourth magnetic powder sheet 106 is coupled to the third magnetic powder sheet 104, the second recess 132 and the second protrusion 134 are first. It is oriented so as to extend in the same direction as the recess 128 and the first protrusion 130. The second recess 132 is designed to enclose the first protrusion 130. Although this embodiment shows recesses and protrusions in the third and fourth magnetic powder sheets, the recesses or protrusions formed in these sheets deviate from the scope and ideas of this exemplary embodiment. It can be omitted without doing anything.

When forming the first magnetic powder sheet 100 and the second magnetic powder sheet 102, the first magnetic powder sheet 100 and the second magnetic powder sheet 102 form the first part 140 of the small power inductor 100. As such, for example, by hydraulic pressure, they are integrally pressed at high pressure and laminated with each other. In addition, the third magnetic powder sheet 104 and the fourth magnetic powder sheet 106 will also be stamped together to form the second portion of the small power inductor 100. In this embodiment, the plurality of clips 108, 110, 112 of the first portion 140 so that the plurality of clips extend a certain distance beyond both sides of the first portion 140 of the small power inductor 100. It is placed on the top surface 118. This distance is equal to or greater than the height of the first portion 140 of the small power inductor 100. Immediately after the plurality of clips 108, 110, 112 are properly positioned on the top surface 118 of the first portion 140, the second portion is placed on the top of the first portion 140. The first and second parts 140 of the small power inductor 100 will then be stamped together to form the finished small power inductor 100.

Some of the clips 108, 110, 112 extending beyond both edges of the small power inductor 100 include a first termination 142, a second termination 144, and a third termination 146. It will be bent around the first portion 140 to form a fourth termination 148, a fifth termination 150, and a sixth termination 152. These terminations 150, 152, 142, 146, 144, 148 allow the small power inductor 100 to be properly coupled to the circuit board or printed circuit board. In this embodiment, the physical gap between the winding and the core, which is typically found in conventional inductors, is removed. Elimination of this physical gap tends to minimize audible noise from the vibration of the windings.

Multiple windings 108, 110, 112 will be formed from a conductive copper layer and these windings will be deformed to achieve the desired shape. Conductive copper materials are used in this embodiment, but any conductive material may be used without departing from the scope and ideas of this exemplary embodiment.

Although only three clips are shown in this embodiment, more or fewer clips may be used without departing from the scope and ideas of this exemplary embodiment. Although these clips are shown in the form of parallel geometry, they may be in series depending on the trace geometry of the circuit board.

The magnetic sheet between the first magnetic powder sheet and the second magnetic powder sheet is not shown, but without departing from the scope and ideas of this exemplary embodiment, because the windings are small power inductors. The magnetic sheet may be placed between the first magnetic powder sheet and the second magnetic powder sheet as long as it is long enough to properly form the terminals of. In addition to this, the two magnetic powder sheets are shown to be located above the multiple windings 108, 110, 112, but deviate from the scope and ideas of this exemplary embodiment. No, more or less sheets may be used to increase or decrease the core area.

In this embodiment, the magnetic field is generated in a direction perpendicular to the direction of particle orientation, which will achieve lower inductance or in a direction parallel to the direction of particle orientation. This will result in higher inductance depending on the direction in which the magnetic powder sheet is extruded.

The moldable magnetic material that defines the magnetic material 162 may be any of the materials described above or any other suitable material known in the art. Exemplary magnetic powder particles for producing the magnetic layers 101, 102, 104, 106, 108 are ferrite particles, iron (Fe) particles, sentust (Fe-Si-Al) particles, MPP (Ni-Mo-). Fe) particles, High Flux (Ni-Fe) particles, Megaflux (Fe-Si alloy) particles, iron-based amorphous powder particles, cobalt-based amorphous It will contain powdered particles or even materials known in the art. When these magnetic powder particles are mixed with a polymer binder material, the resulting magnetic material has a gap dispersion property that does not require physical gaps or separation of parts of different magnetic materials. Shown. Therefore, it is advantageous to avoid the problems and costs associated with ensuring and maintaining a uniform physical gap size. For high current applications, a pre-annealed magnetic amorphous metal powder in combination with a polymer binder would be advantageous.

Although a magnetic powder material mixed with a binder is considered to be advantageous, both the powder particles and the non-magnetic binder material are not always required for the magnetic material forming the magnetic material 162. In addition to this, the moldable magnetic material does not necessarily have to be provided in the form of the sheets or layers described above, but rather to the coil 164 using compression molding methods or other methods known in the art. It may be directly combined. The magnetic material 162 shown in FIG. 6 is generally elongated and rectangular, but other shapes of the magnetic material 162 can be adopted.

In various embodiments, the magnetic component 100 is a transformer in DC (DC) power applications, single-phase voltage converter power applications, two-phase voltage converter power applications, three-phase voltage converter power applications, and multi-phase voltage converter power applications. Or it will be clearly adapted for use as an inverter. In different embodiments, in order to achieve different purposes, the coils 108, 110, 112 are placed in series or in parallel, either inside the component itself or through a circuit on which the component is mounted. Will be electrically connected.

When two or more independent coils are provided within a magnetic component, these coils will be arranged so that the magnetic fields are shared between the coils. That is, these coils will utilize a common flux path through a portion of a single piece of magnetic material.

FIG. 5 shows an exemplary coil 420 that may be manufactured as a generally flat element by punching metal, printing techniques, or other manufacturing methods known in the art. The coil 420 is generally C-shaped as shown in FIG. 5, and has a generally straight first conductive path 422 and a generally straight second conductive path 422 that extends at right angles to the first conductive path 422. It includes a conductive path 424 and a third conductive path 426 that extends generally at right angles to the second conductive path 424 and is generally arranged in a direction generally parallel to the first conductive path 422. Coil ends 428, 430 are defined at the distal ends of the first and third conductive paths 422, 426, and 3/4 turns are provided throughout the coil 420 within the conductive paths 422, 424, 426. The inner peripheral edge of coil 420 defines the central flux area A (shown by the imaginary line in FIG. 5). Area A defines an internal region through which the magnetic flux passage may be passed when magnetic flux is generated within the coil 422. In other words, area A is a magnetic flux passage extending between the conductive path 422 and the conductive path 426 and between the conductive path 424 and the imaginary line connecting the coil ends 428 and 430. including. When a plurality of such coils 420 are used in a magnetic body, their central flux regions will be partially overlapped with each other in order to couple the coils together. Although a particular coil shape is shown in FIG. 5, it should be understood that in other embodiments, another coil shape with similar effects may be used.

FIG. 6 shows a cross section of some coils 420 in the magnetic material 440. In the embodiments shown, the magnetic material is made of magnetic metal powder particles surrounded by a non-magnetic material, in which case adjacent metal powder particles are separated from each other by the non-magnetic material. Instead, other magnetic materials may be used in other embodiments. Magnetic materials will have gap dispersion properties that eliminate the need for discrete core pieces that must be physically gapped from each other.

A coil, such as coil 420, is located within the magnetic material 440. As shown in FIG. 6, area A1 represents the central flux area of the first coil, area A2 represents the central flux area of the second coil, and area A3 represents the central flux area of the third coil. Represent. Depending on the placement of the coils within the magnetic 440 (ie, the spacing between the coils), areas A1, A2, A3 will overlap, but the coupling of the coils to each other will span the entire various parts of the magnetic 440. It will not completely overlap so that it can be changed. In particular, the coils may be biased or staggered with respect to each other in the magnetic body so that some, but not all, of the area A defined by each coil overlaps another coil. In addition, the coils may be placed in the magnetic body so that part of the area A within each coil does not overlap any other coil.

Within the non-overlapping portion of the area A of the adjacent coil in the magnetic body 440, a part of the magnetic flux generated by each coil generates the central magnetic flux area without passing through the central magnetic flux area A of the adjacent coil. Return only within the central flux area of each coil to be made to.

Within the overlapping area of area A of the adjacent coil in the magnetic body 440, a part of the magnetic flux generated by each coil returns to the central magnetic flux area A of each coil that generates it, and is adjacent. It passes through the overlapping central flux area A of the coil.

By changing the degree of the overlapping portion and the non-overlapping portion of the central magnetic flux region A of the coil, it is possible to change the coupling between the coils. In addition, by varying the separation distance in the direction perpendicular to the plane of the coil (ie, by placing the coil in a separated plane), the reluctance of the flux path is varied across the magnetic body 140. right. The product of the overlapping central flux areas of adjacent coils and the special distance between the coils determines the cross-sectional area of the magnetic body through which the common flux path passes through the magnetic body 440. By varying this cross-sectional area, the reluctance will be altered with associated performance advantages.

27-33 include simulation and test results, as well as comparative data, for conventional magnetic components with discrete core pieces in which physical gaps are created for embodiments of the gap dispersion core of the present invention. The information shown in FIGS. 27-33 also relates to the coupling features of exemplary embodiments of parts using the methods described in connection with FIG.

FIG. 7 schematically illustrates a magnetic component assembly 460 with several coils arranged within a magnetic body 462 as described above with a partially overlapping and partially non-overlapping magnetic flux zone A. Shown in. Although four coils are shown in assembly 460, more or fewer coils may be used in other embodiments. Each of these coils is similar to the coil 420 shown in FIG. 5, but coils of other shapes can be used in different embodiments.

The first coil is indicated by coil ends 428a, 430a extending from the first surface of the magnetic material 462. The first coil will extend in the first plane within the magnetic material 462.

The second coil is indicated by coil ends 428b, 430b extending from the second surface of the magnetic material 462. This second coil will extend in a second plane within the magnetic material 462 separated from the first plane.

The third coil is indicated by coil ends 428c, 430c extending from the third surface of the magnetic material 462. This third coil will extend in a third plane within the magnetic material 462 separated from the first and second planes.

The fourth coil is indicated by coil ends 428d, 430d extending from the fourth surface of the magnetic material 462. This fourth coil will extend in a fourth plane within the magnetic material 462 separated from the first, second and third planes.

The first, second, third, and fourth planes, or sides, define the generally orthogonal magnetic material 462 shown. It can be seen that the corresponding central flux zones A for the first, second, third, and fourth coils overlap each other in various ways. Part of the central flux zone A for each of the four coils does not overlap with the other coils. The other part of the central flux area A of each coil overlaps one of the other coils. Yet another portion of the central flux area of each coil overlaps with two of the other coils. In yet another portion, the magnetic flux region of each coil closest to the center of the magnetic material 462 in FIG. 7 overlaps with each of the other three coils. Therefore, major changes in coil coupling are realized in various parts of the magnetic material 462. Furthermore, by changing the spatial distance between the planes of the first, second, third, and fourth coils, it is possible to realize a large change in the reluctance in the magnetic flux path.

In particular, the spacing between the planes of the coils does not necessarily have to be the same, so that some coils are positioned closer to (or farther apart) from each other in the assembly than others. It is possible. In this case as well, the central magnetic flux area of each coil and the distance from the adjacent coil in the direction perpendicular to the plane of each coil define the cross-sectional area through which the generated magnetic flux passes through the magnetic body. By varying the spatial distance of the coil plane, the cross-sectional area associated with each coil will vary between its at least two coils.

As with the other embodiments described, the various coils in the assembly will be connected to different phases of power in some applications.

FIG. 8 shows another embodiment of a magnetic component assembly 470 having two coils 420a, 420b that partially overlap and do not partially overlap each other in the flux zone A. As shown in the form of a cross section in FIG. 9, the two coils are located in different planes within the magnetic body 472.

FIG. 10 shows another embodiment of a magnetic component assembly 480 having two coils 420a, 420b that partially overlap and do not partially overlap each other within its flux area A. As shown in the form of a cross section in FIG. 11, the two coils are located in different planes within the magnetic body 482.

FIG. 13 shows another embodiment of a magnetic component assembly 490 having four coils 420a, 420b, 420c, 420d that partially overlap and do not partially overlap each other within its flux zone A. As shown in the form of a cross section in FIG. 11, the four coils are located in different planes within the magnetic body 492.

14 to 17 show embodiments of the magnetic component assembly 500 having a coil configuration similar to the coil configurations shown in FIGS. 8 and 9. Coil 501, 502 includes a wrap around terminal end 504 that extends around the side of the magnetic material 506. The magnetic material 506 may be formed as described above or as known in the art and will have a layered or non-layered structure. Assembly 500 will be surface mounted on the circuit board via the terminal end 504.

FIG. 34 shows another embodiment of a magnetic component assembly 620 having a coupled inductor and illustrating its relationship to a circuit board layout. The magnetic component 620 will be configured and behave similarly to the magnetic components described above, but will be used with different circuit board layouts to achieve different effects.

In the illustrated embodiment, the magnetic component assembly 620 is adapted for voltage converter power applications, so that the first set of conductive windings 622a, 622b, 622c within the magnetic body 626 Includes two sets of conductive windings 624a, 624b, 624c. Each of the windings 622a, 622b, 622c and the windings 624a, 624b, 624c has completed 1/2 turn, for example, in the inductor body, but instead, in other embodiments, it has completed in the winding. There may be more or less turns. The coils will be physically coupled to each other due to their physical positioning within the magnetic material 626 and their shape.

An exemplary circuit board layout, ie "footprints" 630a, 630b, for use with the magnetic component assembly 620 is shown in FIG. As shown in FIG. 34, each of the layouts 630a, 630b includes three conductive paths 632, 634, 636, each defining a 1/2 turn winding. Layouts 630a, 630b are provided on circuit board 638 (shown by imaginary lines in FIG. 34) using known techniques.

When the magnetic component assembly 620 is surface mounted on layouts 630a, 630b to electrically connect component coils 622,624 to layouts 630a, 630b, the overall coil winding path formed is 3 for each phase. It will be understood that it is a turn. Each 1/2 turn coil winding in part 620 is connected to the 1/2 turn winding in board layouts 630a, 630b and these windings are connected in series, thereby for each phase. A total of 3 turns will be brought.

As an alternative, as Figure 34 shows, the same magnetic component assembly 620 has a different circuit board layout 640a, on a different circuit board 642 (shown by the imaginary line in Figure 34) to achieve different effects. It may be connected to 640b. In the specific examples shown, layouts 640a, 640b include two conductive paths 644, 646, each defining a 1/2 turn winding.

When the magnetic component assembly 620 is surface mounted on layouts 640a, 640b to electrically connect component coils 622,624 to layouts 640a, 640b, the overall coil winding path formed is 2.5 turns for each phase. It will be understood that there is.

This component is sometimes referred to as a programmable coupling inductor because the effect of component 620 can be varied by changing the circuit board layout to which component 620 is connected. That is, the degree of coil coupling can be changed according to the circuit board layout. Therefore, it is possible to have substantially the same part assembly 620, but if different layouts are given for that part, the behavior is that the part is one or more circuit boards. It will vary depending on where you are connected to. Changes in the circuit board layout will be realized on the same circuit board or on different areas of different circuit boards.

Many other variants are possible. For example, a magnetic component assembly would contain five coils, each embedded within a magnetic body, each with a 1/2 turn, and the magnetic component would allow the user to complete the winding turns on the circuit board. It can be used with up to 11 different increasing inductance values selected by the user depending on how the conductive traces are laid out.

35 and 36 show another magnetic component assembly 650 with coupling coils 652, 654 within the magnetic material 656. These coils 652 and 654 are symmetrically coupled within the area A2 of the magnetic material 656, while they are uncoupled within the areas A1 and A3 in FIG. The degree of coupling within area A2 can be varied depending on the distance of the coils 652, 654.

FIG. 37 shows the advantages of multiphase magnetic components with coupling coils in the embodiments described above over the multiple discrete uncoupled magnetic components used for each phase as is traditionally done. Specifically, when using a multiphase magnetic component with a coupling coil, such as the coupling coil described herein, the ripple current is at least partially canceled.

18-20 show another magnetic component assembly 520 having several partial turn coils 522a, 522b, 522c, 522d within the magnetic material 524. As shown in FIG. 17, each coil 522a, 522b, 522c, 522d has a 1/2 turn. Four coils 522a, 522b, 522c, 522d are shown, but as an alternative, more or fewer coils can be provided.

Each coil 522a, 522b, 522c, 522d may be connected to another 1/2 turn coil that may be provided, for example, on a circuit board. Each coil 522a, 522b, 522c, 522d comprises an enclosing terminal end 526 that may be surface mounted on a circuit board.

21 to 23 show another magnetic component assembly 540 having several partial turn coils 542a, 542b, 542c, 542d within the magnetic material 544. It can be seen that the coils 542a, 542b, 542c, 542d have a different shape than the coils shown in FIG. Four coils 542a, 542b, 542c, 542d are shown, but as an alternative, more or fewer coils can be provided.

Each coil 542a, 542b, 542c, 542d may be connected to another partial turn coil that may be provided, for example, on a circuit board. Each coil 542a, 542b, 542c, 542d has an enclosing terminal end 546 that can be surface mounted on a circuit board.

24 to 26 show another magnetic component assembly 560 having several partial turn coils 562a, 562b, 562c, 562d within the magnetic material 564. It can be seen that the coils 562a, 562b, 562c, 562d have different shapes than the coils shown in FIGS. 18 and 24. Four coils 562a, 562b, 562c, 562d are shown, but as an alternative, it is possible to have more or fewer coils.

Each coil 562a, 562b, 562c, 562d may be connected to another partial turn coil that may be provided, for example, on a circuit board. Each coil 562a, 562b, 562c, 562d comprises an enclosing terminal end 526 that may be surface mounted on a circuit board.

38 to 40 show various diagrams of another exemplary embodiment of the miniaturized magnetic component 700. More specifically, FIG. 38 shows an assembly in a perspective view, FIG. 39 is a plan view, and FIG. 40 is a bottom view.

As shown in these figures, the assembly 700 generally contains a rectangular magnetic body 702, which comprises a top surface 704, a bottom surface 706 located opposite the top surface, and a top surface 702 and a bottom surface 704. Includes interconnected end faces 708, 710 located on opposite sides and lateral sides 712, 174 interconnected with end faces 708, 710 and upper surface 702 and lower surface 704 located on opposite sides. The bottom surface 706 is abutted and surface mounted on the circuit board 716 to complete the electrical connection from the circuit on the board 716 to the plurality of coils 718, 720 (FIG. 40) in the magnetic body 702. right. The coils 718 and 720 are arranged inside the magnetic body 702 in a relationship that shares a magnetic flux, and in an exemplary embodiment, the magnetic body 702 and its associated coil 720 form a coupled power inductor. Each of the coils 718 and 720 will carry power in different phases.

In an exemplary embodiment, the magnetic material 702 is a monolithic or integral body made of a material with gap-dispersed magnetic properties. Any of the magnetic materials described above or described in the relevant applications identified herein and, optionally, other magnetic materials known in the art are used to form the magnetic body. Will be done. In one embodiment, the magnetic material 702 is made from a moldable material with gap dispersion properties and is molded around coils 718, 720. In another embodiment, the magnetic material 702 will be manufactured from multiple stacked magnetic sheets, such as the multiple stacked magnetic sheets described above. In addition to this, a combination of different magnetic materials will be used to form an integral magnetic material.

In the specific examples shown in FIGS. 38 to 40, the magnetic material is manufactured from a first magnetic material 722 having a first magnetic property and a second magnetic material 724 having a second magnetic property. ing. The first magnetic material 722 defines most of the magnetic material 702 in terms of overall size and shape, and the second magnetic material 724 is the portion of the first magnetic material shown in FIGS. 38-40. And the parts of the coils 718 and 720 are separated. Due to the different magnetic properties of the second material 724, the second magnetic material 724 effectively has a magnetic gap between each part of the first magnetic material and between the coils 718 and 720 adjacent to each other. It still maintains the substantially solid body surrounding the coils 718, 720, without the traditional challenge of physically gapped discrete core pieces in a small assembly. In an exemplary embodiment, the second magnetic material 724 is a magnetic material mixed with a filler material such as an adhesive, and thus the second magnetic material is different from the first magnetic material 722. It has magnetic properties. In an exemplary embodiment, the first magnetic material 722 will be used to form the magnetic material in the first manufacturing stage, and the second material will be used to complete the magnetic material 704. , Can be applied to gaps or cavities formed within the first material.

As can be seen in FIGS. 38 to 40, the second magnetic material 724 includes the upper surface 704 and the lower surface 706 of the magnetic material 702, the end faces 708 and 710 located opposite to each other, and the lateral sides 712 and 714. Extends to. In addition to this, the second magnetic material 724 extends to the internal portion of the magnetic material 702 between the coils 718 and 720. As can be seen from FIGS. 38 and 39, the second magnetic material 724 extends within and along the first plane extending substantially perpendicular to the plane of the circuit board 716. The part of the first magnetic material 722 is separated. As can be seen from FIGS. 38 and 40, the second magnetic material 724 also extends in the second plane extending substantially parallel to the plane of the circuit board 716 and is coiled in the second plane. Separate the parts 718 and 720 from the first magnetic material 722. That is, the second magnetic material 724 separates the first magnetic material 722 in vertical and horizontal planes that intersect the two and are perpendicular to the circuit board 716.

As shown in FIG. 40, coils 718, 720 are flat coils, but other types of coils, including any coil described above or in related applications, may be used in another embodiment. .. Further, each of the coils 718, 720 defines the number of first partial turns of the winding, as in the embodiment described above with reference to FIG. The circuit board 716 will include a layout that defines the number of second partial turns of the winding. The total number of turns in the completed assembly is the sum of the number of turns realized in the coils 718, 720 and the number of turns realized on the circuit board layout. Different numbers of turns will be offered to serve different purposes.

Each of the coils 718, 720 includes surface mount terminals in the form of contact pads 726, 728 that are exposed on the underside 706 of the magnetic material 702 to establish electrical connections to the circuits on the circuit board 716. However, as an alternative, it is envisioned that other surface mount terminal structures may be used with through-hole terminals in various embodiments. In this illustrated embodiment, the contact pads 726, 728 define an asymmetric pattern on the bottom surface 706 of the magnetic material, but other patterns or arrangements of surface mount terminals can be employed.

Assembly 700 offers many advantages over existing power inductors. Magnetic material 702 has a smaller foot than an assembly that uses discrete cores that are physically gapped, while still achieving improved inductance values, higher efficiency, and increased energy density. It can be installed in a smaller package with a print. In addition, AC winding loss is also significantly reduced compared to conventional inductor assemblies with discrete core pieces that are physically gapped, while still achieving adequate suppression of leakage flux. Will be. In addition to this, this assembly provides greater freedom in the circuit board layout used to connect to the coil, while conventional inductors of this type, along with only a limited type of circuit board layout. Was only available. In particular, unlike conventional power inductors of this type, different phases of power can share the same layout on the circuit board.

41 and 42 are perspective views and side views of another embodiment of the magnetic component assembly 750, respectively. The assembly 750 contains a magnetic material 752 integrally manufactured from a material having gap dispersion properties by the molding or stamping operations described above. Similar to the above embodiment, the magnetic material 752 has an upper surface 754, a lower surface 756, end faces 758, 760 located on opposite sides, and lateral sides 762, 764 located on opposite sides. Including. The bottom surface 756 is in abutment contact with the circuit board 766 to complete the electrical connection between the circuit on the substrate 788 and the coils 778, 780 in the magnetic body 752.

Unlike the embodiments described above, the magnetic material comprises physical gaps 782, 784 formed within a portion of the magnetic material. In the embodiments shown in FIGS. 41 and 42, each of the first and second physical gaps 782, 784 is from the central portion 786, 788 of the coil 778, 780, respectively, to the end face 758 of the magnetic material. Extends outward to 760. In the illustrated embodiment, the physical gaps 782, 784 extend generally in the same plane as each other and are substantially parallel to the lower surface 756 of the magnetic body 752 and thus to the plane of the circuit board 756. Extends to. Moreover, in the illustrated embodiment, the physical gaps 782, 784 do not extend completely around the periphery of the magnetic material 752. Rather, the gaps 782, 784 only extend between the coils 778 and 780 and the respective ends 758, 760 of the magnetic material 752. Neither of the gaps 782 and 784 extends into the internal region of the magnetic material 752 between coil 778 and coil 780.

Assembly 750, which uses the integral magnetic material 752 and the integrally formed physical gaps 782 and 784, is physically within the inductor component without the challenge of physically creating gaps in the discrete core structure. Allows the desired characteristics of the gap.

FIG. 43 shows another embodiment of the magnetic material 800 used for inductor components and with circuit board 766. The magnetic material 800 is manufactured from a magnetic material having a gap dispersion characteristic such as any of the materials described above, and extends from the internal region of the magnetic material to the lower surface 810 of the magnetic material 800 that abuts on the circuit board 766. It is formed with a series of physical gaps 802, 804, 806, 808. The physical gaps 802, 804, 806, and 808 extend generally parallel to each other and substantially perpendicular to the plane of the circuit board 766. Each gap 802, 804, 806, 808 is associated with a coil (not shown in FIG. 43, but similar to the coil shown in FIG. 42). Any number of coils and gaps can be provided in this manner.

FIG. 44 shows a series of physical gaps 822, 824, 826, extending from the internal region of the magnetic material to the upper surface 830 of the magnetic material located opposite the lower surface 832 of the magnetic material 800 abutting the circuit board 766. An alternative embodiment of an assembly comprising a magnetic material 820 with 828 is shown. Thus, magnetic 820 is similar to magnetic 800 (FIG. 43), but includes physical gaps 822, 824, 826, 828 that extend away from circuit board 766 instead of extending toward circuit board 766. .. Coil 834, 836, 838, 840 are associated with each of the gaps 822, 824, 826, 828.

FIG. 45 is a side view of another embodiment of the magnetic component assembly 850, wherein the magnetic component assembly 850 has a first magnetic material 854, a second magnetic material 858 different from the first magnetic material, and a first. Includes an integral magnetic material 852 manufactured from a third material 856, which is different from the first and second magnetic materials. Materials 854, 856, 858 will be stamped or molded into the form of a single monolithic part containing coils 860, 862, 864, 866 arranged in a magnetic flux sharing relationship with each other.

The third material 856 may be a magnetic or non-magnetic material in various embodiments and is inserted between the first magnetic material 854 and the second magnetic material 858. The third material separates the first material 854 and the second material 858 along the entire axial length of the magnetic material 852, and within the internal region of the magnetic material 852, the adjacent coils 860 and 862. Extends between and between adjacent coils 862 and 864 and between adjacent coils 864 and 868. A third material, as shown in FIG. 45, is used between a pair of adjacent coils of a plurality of coils to alter the flux path between the coils 860, 862, 864, 866. , May have different thicknesses.

In various embodiments, one or both of the first and second materials 854, 858 are stacked magnetic sheets, moldable magnetic powders, sheet-to-powder combinations, or other known in the art. Including material. Each of the first and second materials 854, 858 will have different degrees of gap dispersion properties, and the third material 865 is the first material 854 and the second in the other solid magnetic material 852. It has sufficiently distinctly different properties for both the first and second materials 854 and 858 in order to effectively form a magnetic gap with the material 858. Therefore, the difficulty of assembling the core pieces with discrete physical gaps is avoided. Assembly 850 by adjusting the relative amounts, proportions and dimensions of the first material 854, the second material 856, and the third material 858 used to form the one-piece magnetic material 852. The electrical performance of the will be changed. In particular, the self-inductance and coupling inductance between the different phases of power carried by each of the coils 860, 862, 864, 866, with the proper selection of materials and the proportion of each material to produce the magnetic material 852. Can be changed by.

III. Exemplified embodiments disclosed

It should be clear that the various features described can be combined and matched in the form of various combinations. For example, when a layered structure is described with respect to a magnetic material, a non-layered magnetic structure can be used instead. A wide variety of magnetic component assemblies can be provided that have different magnetic properties and different numbers and types of coils, and with different performance characteristics to meet the requirements of a particular application. Is advantageous.

Furthermore, it is also advantageous that some of the above features can be used in structures with discrete core pieces that are physically gapped and separated from each other. This is especially true for the coil coupling features described above.

Among the various possibilities within the scope of the disclosure described above, at least the following embodiments are considered to be advantageous over conventional inductor components.

One embodiment of a magnetic component assembly comprising an integral magnetic material made from a material having a gap dispersion property and a plurality of coils located in the magnetic body is disclosed, in which the coils are mutually exclusive. It is arranged in the magnetic body in a relationship that shares magnetic flux.

Optionally, the magnetic material is manufactured from a moldable material that has gap dispersion properties. A monolithic magnetic material can be produced from a first magnetic material having a first magnetic property and a second magnetic material having a second magnetic property, in which case the second magnetic material is , A part of the first magnetic material is separated, and a part of an adjacent coil among a plurality of coils is separated. The second magnetic material can separate at least a part of the first magnetic material from a part of the coil. The second magnetic material can extend to the upper surface and the lower surface of the magnetic material, the end faces located on opposite sides to each other, and the lateral side surface.

Further, optionally adopted, the integrated magnetic material can be manufactured from a first magnetic material having a first magnetic property and a second magnetic material having a second magnetic property, in this case. , The second magnetic material extends in the first plane and in the second plane extending substantially perpendicular to the first plane. One of the first and second magnetic materials further comprises a stamped magnetic sheet. One of the first and second magnetic materials may further contain a magnetic powder. At least one of the first and second magnetic materials can be stamped around multiple coils. The first magnetic material can form a substantially rectangular body, and the first and second magnetic materials can jointly define a solid body around the coil.

The plurality of coils may be flat coils as desired. Each of the multiple coils may define the first partial turn of the winding. The assembly can further include a circuit board, which defines a second partial turn of the winding for each of the multiple coils, the first and second partial turns being connected to each other. ing.

Surface mount terminals may be provided for each of the plurality of coils at the option of adoption. Surface mount terminals will define an asymmetric pattern on the surface of the magnetic material.

A plurality of physical gaps may be formed in the magnetic body at the option of adoption. This physical gap will extend outward from each part of each of the multiple coils to the respective edge of the magnetic material. The assembly can further include a circuit board, and the physical gaps may extend parallel to the plane of the circuit board and be spaced apart from each other and generally coplanar with each other. The physical gap may extend only over the respective ends of the magnetic material located on opposite sides of each other. The coils can be separated from each other and the physical gaps need not extend between adjacent coils.

Alternatively, an optional physical gap extends outward from each of the plurality of coils to the top surface of the magnetic material. The assembly can further include a circuit board, with the physical gap extending substantially perpendicular to the plane of the circuit board. The magnetic material can include a lower surface, which is in contact with the circuit board and the upper surface located on the opposite side of the lower surface.

An optional physical gap may extend outward from each of the plurality of coils to the underside of the magnetic material. The assembly can further include a circuit board and the underside can be in abutment contact with the circuit board. The physical gap can extend substantially perpendicular to the plane of the circuit board. The physical gap can include multiple gaps that are spaced apart and substantially parallel.

The magnetic material may optionally include a first magnetic material, a second magnetic material different from the first magnetic material, and a third material different from the first and second magnetic materials. .. The third material may be a magnetic material. The third material can be inserted between the first magnetic material and the second magnetic material. The third material may have different thicknesses between adjacent coil pairs of multiple coils. The first material, the second material, and the third material can be pressed against each other. At least one of the first and second materials may include a stacked magnetic sheet. At least one of the first and second materials may comprise a moldable magnetic powder. The first and second magnetic materials may have gap dispersion properties.

The magnetic material and the coil can form a coupled power inductor. Each of the coils can be shaped to carry power of different phases.

IV. Conclusion

It is believed that the advantages of the present invention will be apparent from the above-mentioned specific examples and embodiments. Although many embodiments and embodiments have been specifically described, other embodiments and embodiments can be envisioned within the scope and ideas of the disclosed exemplary devices, assemblies, and methods. ..

This described description is for the purpose of disclosing the present invention, including the best aspects, and also for those skilled in the art to make and use any device or system and any incorporated method. Specific examples are used to enable the practice of the present invention including. The patentable scope of the present invention will be defined by the claims and will include other specific examples conceived by those skilled in the art. These other examples have structural elements that do not differ from the word-for-word of the claims, or an equal structure with slight differences from the word-for-word of the claims. If it contains elements, it is intended to be within the claims.