Methods for manufacturing integrated magnetic components and led power supply

Abstract

The present disclosure provides an integrated magnetic component, a method for manufacturing the integrated magnetic component, and an integrated LED power supply including the magnetic component. The integrated magnetic component includes a PCB baseboard, wherein magnetic core, copper coils and pins are embedded in the baseboard. The magnetic core may be an iron or cobalt-based soft magnetic thin film(s), and it may be stuck or coated on the inner layer of the PCB baseboard. Further, the copper coil may be thin copper tracks. The present disclosure provides a method for making iron or cobalt-based nanocrystalline strip(s) using a soft magnetic thin film deposition method, or a melt spinning method. The iron or cobalt-based soft magnetic thin film(s) may then be used to make an embedded PCB magnetic core. The resulting magnetic component is thin, highly efficient, and functions as a substrate in the assembly process. In addition, the LED power supply consistent with the present disclosure is thin and small, highly integrated, with process repeatability and reliability. Embodiments consistent with the present disclosure thus simplify the system assembly process for making LED power supplies, and save time and cost in the process.