Bobbin apparatus for reducing gap losses in magnetic components

摘要

A bobbin apparatus and associated magnetic component is configured to reduce gap losses associated with a core air gap in a bobbin-wound magnetic component such as an inductor or transformer. The bobbin includes a step structure protruding from the winding surface between bobbin ends. The step is operable to provide spacing between the conductive windings disposed on the bobbin and the core air gap inside the bobbin axial passage. The spacing reduces stray flux interactions with the conductive winding, thereby reducing gap losses and preventing undesirable heating of the winding and core. Additional winding configurations and methods for use with the bobbin apparatus are also provided.

主权项

1. A bobbin apparatus for supporting a core assembly, the core assembly including an air gap having an axial gap distance, the bobbin apparatus comprising:
a bobbin body having a first bobbin end and a second bobbin end, the second bobbin end spaced from the first bobbin end; an axial passage defined through the bobbin body between the first and second bobbin ends, the bobbin body including an inner passage surface substantially facing the axial passage, the core assembly insertable into the axial passage with the air gap of the core assembly located at an air gap position between the first and second bobbin ends; a winding surface disposed on the bobbin body between the first and second bobbin ends; and a step having an outer step surface protruding from the winding surface between the first and second bobbin ends, the step located on the winding surface in substantial alignment with the air gap position, the step having a step height defined as the distance between the inner passage surface and the outer step surface, wherein the step height is at least as great as the axial gap distance, wherein the step further comprises an axial step width at least as great as twice the axial gap distance.