Stacked step gap core devices and methods

摘要

A core apparatus for a magnetic component includes first and second E-cores stacked with legs extending in the same direction. The first E-core includes a middle first core leg having a middle first core leg length, and the second E-core includes a middle second core leg having a middle second core leg length greater than the middle first core leg length such that a step is formed between the distal ends of the middle legs of the first and second E-cores. A third E-core may be positioned opposite the stacked first and second E-cores forming a stepped air gap between the middle first and second core legs and the middle third core leg.

主权项

1. A core apparatus for a magnetic component, comprising:
a first E-core having a first core thickness and including
a first outer first core leg and a second outer first core leg, each having an outer first core leg length, anda middle first core leg having a middle first core leg length, the middle first core leg length being less than the outer first core leg length by a middle first core offset; a second E-core having a second core thickness and including
a first outer second core leg and a second outer second core leg, each having an outer second core leg length, anda middle second core leg having a middle second core leg length greater than the middle first core leg length, the middle second core leg length being less than the outer second core leg length by a middle second core offset less than the middle first core offset; wherein the first and second E-cores are stacked against each other such that the middle first core leg and the middle second core leg extend in substantially the same direction; wherein a difference between the middle first core offset and the middle second core offset forms a stepped end profile at exposed ends of the middle first core leg and the middle second core leg; and a third E-core positioned opposite the stacked first and second E-cores, the third E-core being a single non-stacked core and including a first outer third core leg, a second outer third core leg, and a middle third core leg, the middle third core leg having a constant middle third core leg length extending toward the stacked middle first and second core legs, the middle third core leg being shorter than the first and second outer third core legs by a middle third core leg offset, the middle third core leg offset being less than the middle second core offset, the third E-core having a third core thickness substantially equal to the sum of first and second core thicknesses.