JP4189745B2 - Choke coil, transformer, and manufacturing method thereof - Google Patents

Description

The present invention relates to a choke coil and a transformer used in a DC-DC converter and the like, and a manufacturing method thereof .

  A DC-DC converter that converts a DC voltage includes a transformer that steps up or down an input voltage, and a choke coil that smoothes an output voltage. Both the transformer and the choke coil include a core member, a bobbin and a winding.

  As shown in FIG. 4, a conventional upper and lower split converter transformer (see Patent Document 1) includes an upper core member 100, a bobbin 101 and a low voltage winding 102, and a lower core member 105, a bobbin 106 and a low voltage winding. It includes a wire 107 and an insulating member 110 interposed therebetween. The upper and lower high-voltage windings are housed in bobbins 101 and 106, respectively.

When the low-voltage windings 102 and 107 are formed of edgewise coils as in this conventional example, the core members 100 and 105 cannot be wound around the outer peripheral surface because of high rigidity. Therefore, the edgewise coils 102 and 107 are manufactured in advance in a separate process and accommodated in the bobbins 101 and 106, and then the bobbins 101 and 106 and the edgewise coils 102 and 107 are integrally fitted to the core members 100 and 105. .
JP 2003-17334 A

  The edgewise coils 102 and 107 form a kind of coil spring, are supported at both ends, and there is a gap between adjacent turn portions (ring portions). For this reason, resonance may occur with an inherent spring constant when vibration is applied to the transformer. Due to resonance, stress may be applied to the connection portion between the edgewise coils 102 and 107 and the lead wire connected thereto, and the connection portion may be damaged. Further, the turn portions of the edgewise coils 102 and 107 collide with each other due to vibration, and the insulating coating may be peeled off to cause a rare short circuit.

The present invention has been made in view of the above circumstances. A choke coil and a transformer that are integrated with a bobbin after a winding is manufactured in a separate process in advance, and a manufacturing method thereof , according to a spring constant inherent to the winding. The purpose is to suppress resonance.

  The technical idea of the present invention is to prevent vibration of each winding part, that is, relative movement of the winding part by a part of the bobbin when a gap exists between the winding parts of the windings manufactured in advance in a separate process. That is.

(1) A choke coil according to a first invention of the present application is, as described in claim 1, an insulating bobbin having a cylindrical part; a core member including a core part inserted into a hollow hole of the cylindrical part of the bobbin; A spirally wound winding located outside the outer peripheral surface of the cylindrical portion of the bobbin. On the outer peripheral surface of the cylindrical part, a movement preventing part composed of a helical protrusion that is inserted into a helical gap between adjacent winding parts of the winding and prevents relative movement in the axial direction of each winding part is formed. The protrusion is an incomplete thread at the tip of the cylindrical portion.

  In this choke coil, the movement preventing portion of the cylindrical portion of the bobbin prevents relative movement between the winding portions. That is, each winding part cannot move in the thickness direction, that is, the axial direction of the choke coil.

A choke coil according to a second aspect is the edgewise coil according to the first aspect, wherein the winding is made of a strip-shaped rectangular copper wire. Choke coil of claim 3, in claim 1 or 2, spiral ridge is Ru are formed at the same pitch as the helical gap. According to a fourth aspect of the present invention, there is provided a choke coil manufacturing method comprising: an insulating bobbin having a cylindrical part; a core member including a core part inserted into a hollow hole of the cylindrical part of the bobbin; and an outer peripheral surface of the cylindrical part of the bobbin. A choke coil manufacturing method comprising: a spirally wound winding positioned outside; and a helical gap between adjacent winding portions of the winding is fitted on an outer peripheral surface of the cylindrical portion. Then, while preventing relative movement in the axial direction of each winding part and forming a movement prevention part consisting of a helical protrusion that is an incomplete thread at the tip of the cylindrical part, the winding is rotated, A choke coil is manufactured by inserting the spiral protrusion between the winding portions into a cylindrical portion of the bobbin by inserting the spiral protrusions between the winding portions.

(2) A transformer according to a second invention of the present application, as described in claim 5, includes an insulating bobbin having a cylindrical part; a core member including a core part inserted into a hollow hole of the cylindrical part of the bobbin; A high-voltage winding spirally wound around the first shaft portion of the outer peripheral surface of the cylindrical portion of the bobbin, and a low-voltage winding spirally positioned outside the second shaft portion. The movement prevention part which consists of a helical protrusion which fits into the helical gap between adjacent winding parts of the low voltage winding on the outer peripheral surface of the cylindrical part and prevents the relative movement of each low voltage winding part in the axial direction. And the protrusion is an incomplete thread at the tip of the cylindrical portion .

  In this transformer, the movement preventing portion of the cylindrical portion of the bobbin prevents the winding portions from being relative to each other. That is, each winding part cannot move in the thickness direction, that is, the axial direction of the transformer.

A transformer according to a sixth aspect is the edgewise coil according to the fifth aspect, wherein the low-voltage winding is formed of a strip-shaped rectangular copper wire. Transformer according to claim 7, in claim 5 or 6, helical ridge is Ru are formed at the same pitch as the windings shaped gap. The transformer manufacturing method according to claim 8 includes an insulating bobbin having a cylindrical part, a core member including a core part inserted into a hollow hole of the cylindrical part of the bobbin, and a first outer peripheral surface of the cylindrical part of the bobbin. A transformer manufacturing method comprising: a high-voltage winding spirally wound around a first shaft portion; and a low-voltage winding spirally wound outside the second shaft portion, the outer periphery of the cylindrical portion On the surface, a helical gap between adjacent winding portions of the low-voltage winding is fitted to prevent relative movement in the axial direction of each winding portion, and an incomplete screw portion is formed at the tip of the cylindrical portion. A movement preventing portion made of a helical protrusion is formed, the low-voltage winding is rotated, and the helical protrusion is inserted into the helical gap between the winding portions to thereby connect the low-voltage winding to the bobbin. A transformer is manufactured by screwing into a cylindrical portion .

(1) According to the choke coil of the first invention and the choke coil manufacturing method according to the fourth aspect , the movement preventing portion prevents relative movement, that is, vibration of each winding portion. That is, all the winding parts are integrated by the movement preventing part. Since there is no collision between adjacent winding portions, damage to the connecting portion between both ends of the winding and the lead wire is prevented. Further, since the protrusion is an incomplete threaded portion at the tip of the cylindrical portion, the bobbin can be easily screwed into the winding at the initial stage of the connection between the bobbin and the winding .

  Further, since the winding portions do not collide with each other, the insulation between them is maintained, and in some cases, it can be eliminated. In addition, this can be achieved only by forming the vibration preventing portion on the outer peripheral surface of the cylindrical portion of the bobbin, and an increase in cost can be minimized.

According to the choke coil of the second aspect, it is possible to prevent a collision between the turn portions in the edgewise coil which has a large cross-sectional area and easily causes relative movement. According to the choke coil of the third aspect, not only is the collision between the winding portions prevented, but the protrusions form the male screw and the gap between the winding portions forms the female screw, so that the bobbin and the winding can be easily coupled. ing to.

(2) According to the transformer according to the second invention and the transformer manufacturing method according to the eighth aspect , the movement preventing portion prevents relative movement, that is, vibration of each winding portion. Since there is no collision between adjacent winding portions, damage to the connecting portion between both ends of the winding and the lead wire is prevented. Further, since the winding portions do not collide with each other and the insulation between them is maintained, the thickness of the insulating coating on the surface can be reduced. In addition, an increase in cost can be achieved only by forming the vibration preventing portion on the outer peripheral surface of the cylindrical portion of the bobbin. Further, since the protrusion is an incomplete threaded portion at the tip of the cylindrical portion, the bobbin can be easily screwed into the winding at the initial stage of the connection between the bobbin and the winding .

According to the transformer of the sixth aspect, it is possible to prevent a collision between the turn portions in the edgewise coil having a large cross-sectional area and easily causing relative movement. According to the transformer of claim 7, not only is the collision between the winding portions prevented, but the protrusions form the male threads and the gaps between the winding portions form the female threads, so that the bobbin and the windings can be easily coupled. that Do not.

<Choke coil>
The choke coil includes a bobbin, a core member, and a winding. In addition, a cover etc. can be included as needed. Among these, the bobbin is made of an insulating material, includes at least a cylindrical portion, and can further include a collar portion (flange portion). The movement preventing portion formed on the outer peripheral surface of the cylindrical portion includes a spiral protrusion and a plurality of protrusions formed along a spiral locus. The protrusions or protrusions are formed corresponding to the gaps between the winding portions of the winding.

  The core member includes a core portion that is inserted into the hollow hole of the cylindrical portion of the bobbin, and may further include a bottom portion and a side wall. Although it can consist of a single member, it is desirable to consist of a pair of members.

  The winding is composed of a plurality of winding portions (turn portions) and extends in a spiral shape as a whole. A gap in the thickness direction (axial direction of the winding) is formed between adjacent winding portions, and extends in a spiral shape as a whole.

Although there are no particular restrictions on the cross-sectional shape and dimensions of each winding portion, the present invention is particularly effective in the case of a so-called edgewise coil made of a strip-like rectangular copper wire. Whatever the name of the winding, there is a gap between the windings, and helical windings that collide with each other when vibration is applied to the choke coil are included in the present invention.
<Transformer>
The transformer includes a bobbin, a core member, a low voltage winding and a high voltage winding. In addition, a cover etc. can be included as needed. The high voltage winding wound around the first shaft portion of the bobbin has a large number of turns, and a thin wire with a circular cross section is wound around the bobbin. Therefore, there is usually no gap between adjacent winding portions, and the collision of the winding portions due to vibration does not cause a problem.

  On the other hand, the low voltage winding with a small number of windings located on the outer side in the radial direction of the second shaft portion of the bobbin is often composed of an edgewise coil or the like, similar to the winding of the choke coil. Therefore, the same problem as the choke coil winding occurs, and the present invention is applied. The low-voltage winding is the primary side in the step-up DC-DC converter and the secondary side in the step-down type.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
<First embodiment>
(Constitution)
1 and 2 show a first embodiment. This embodiment is a case where the present invention is applied to a choke coil of a DC-DC converter.

  The choke coil includes a bobbin 10, a core member 20, a winding 30 and a cover 40. Of these, the bobbin 10 is made of an insulating material and includes a cylindrical portion 11 and a flange portion 15 formed at the upper end thereof and radially outward. A helical protrusion 12 is formed on the outer peripheral surface of the cylindrical portion 11. The pitch coincides with the pitch of the winding portion 32 of the winding 30 described below, and the cross-sectional shape is a triangle or trapezoid (see FIG. 2). In addition, an incomplete screw portion 12a similar to the tip of a male screw of a general bolt is formed at the tip (lower end).

  The core member 20 is made of a ferrite material and includes an upper core 21 and a lower core 26, both of which have a substantially symmetrical shape. The upper core 21 has a rectangular ceiling portion 22, a columnar core portion 23 extending downward from the center portion thereof, and a pair of side wall portions 24 extending downward from both sides of the ceiling portion 22. When viewed from the end face direction, it has an E shape.

  The lower core 26 has a rectangular bottom portion 27, a columnar core portion 28 extending upward from the central portion thereof, and a pair of side wall portions 29 extending upward from both sides of the bottom portion 27. It has a letter shape. The core parts 23 and 28 are opposed to each other through a space gap, and the side wall parts 24 and 29 are in contact with each other to form a closed magnetic circuit.

  The winding 30 is a so-called edgewise coil composed of a strip-shaped coil. The cross-sectional shape is a flat rectangular shape having a height (thickness) smaller than a width (radial dimension). It has a main body 31 wound in a spiral shape, an input end 35 extending tangentially from the upper end thereof, and an output end 36 extending tangentially from the lower end thereof. A predetermined gap 33 is formed in the height direction between the turn parts (annular parts) 32 constituting the main body part 31. The cover 40 includes a bottom portion 42 having a hole 41 in the center portion and a pair of side portions 44 on both sides thereof.

  As can be seen from FIG. 2 showing the assembled state, the core portion 23 of the upper core 21 and the core portion 28 of the lower core 26 are inserted into the hollow hole 17 of the cylindrical portion 11 of the bobbin 10. When formed on the outer peripheral surface of the cylindrical portion 11 of the bobbin 10, the spiral protrusion 12 is fitted in the gap 33 between the turn portions 32 of the edgewise coil 30. The flange portion 15 of the bobbin 20 is in contact with the upper end surface of the main body portion 31, and the bottom portion 42 of the cover 40 is in contact with the lower end surface thereof. Thereby, each turn part 32 is prevented from moving or vibrating in the vertical direction.

  The pair of side portions 44 of the cover 40 covers a part of the outer peripheral surface of the main body portion 31 of the edgewise coil 30, and the input end portion 35 and the output end portion 36 extend from the opening 43.

  When the choke coil is assembled, the main body portion 31 of the edgewise coil 30 manufactured in a separate process is rotated and screwed into the cylindrical portion 11 of the bobbin 10. Alternatively, the cylindrical portion 11 may be rotated and screwed into the main body portion 31. In either case, the spiral protrusion 12 is screwed into the spiral gap 33. The lower surface side and outer peripheral side thereof are covered with a cover 40. Thereafter, the bobbin 10, the edgewise coil 30 and the cover 40 are attached to the lower core 26, and the upper core 21 is attached.

(Function and effect)
Since the operation of this choke coil is known and is not linearly related to the present invention, its description is omitted.

  According to this embodiment, the following effects can be obtained. First, even if axial vibrations act on the choke coil, the turn parts 32 of the main body part 31 of the edgewise coil 30 are prevented from vibrating with each other. As a result, the stress on the lead wire connection portion due to the resonance of the coil is reduced, the contact between the turn portions 32 of each coil is prevented, the coating is protected, or the coating can be eliminated.

  For example, when this choke coil is mounted on an automobile, vibration is likely to be applied during traveling. However, the ridge 12 is inserted into the gap 33, and all the turn portions 32 are integrated by the ridge 12. Further, the flange portion 15 of the bobbin 10 is pressed against the uppermost turn portion 32, and the bottom portion 41 of the cover 40 is pressed against the lowermost turn portion 32. As a result, since the bobbin 10, the edgewise coil 30, and the cover 40 are integrated, the turn portion 32 cannot vibrate in the axial direction.

  Second, the choke coil for preventing vibration of the turn portion 32 can be modified less. Only the spiral protrusion 12 is formed on the cylindrical portion 11 of the bobbin 10. Moreover, since the portion where the ridge 12 is formed is originally a space, there is no concern that the formation of the ridge 12 will increase the size of the edgewise coil 10 and thus the choke coil (especially the radial dimension).

  Thirdly, since the protrusion 12 has the incomplete screw portion 12a at the lower end, the screwing at the initial stage of the connection between the bobbin 10 and the edgewise coil 30 becomes easy and reliable.

<Second embodiment>
FIG. 3 shows a second embodiment in which the present invention is applied to a transformer of a DC-DC converter.
(Constitution)
Since the configuration of the entire transformer is known, the configuration directly related to the present invention will be mainly described. The bobbin 50 includes a cylindrical portion 51 and a pair of collar portions 52 and 53 formed at an intermediate portion in the axial direction. Three winding portions are partitioned by the upper collar portion 52 and the lower collar portion 53. A wire-shaped primary coil 60 having a circular cross section is wound around the central winding 55a in a spiral shape, and one end and the other end thereof extend outward.

  A strip-shaped upper secondary coil 62 is disposed on the upper winding portion 55b, and a strip-shaped lower secondary coil 66 is disposed on the lower winding portion 55c. One end of the upper secondary coil 62 and the other end (not shown) of the lower secondary coil 66 extend outward, and the other end of the upper secondary coil 62 and one end of the lower secondary coil 64 (none shown). Connected with.

  Spiral ridges 57 and 58 are formed on the upper winding portion 55 b and the lower winding portion 55 c of the cylindrical portion 51 of the bobbin 50 in accordance with the pitches of the upper secondary coil 62 and the lower secondary coil 66. They are fitted into a gap 64 between the turn parts 63 of the upper secondary coil 62 and a gap 68 between the turn parts 67 of the lower secondary coil 66, respectively.

  An upper core member and a lower core member (not shown) are inserted into the hollow hole 59 of the cylindrical portion 51 of the bobbin 50. The bobbin 50 and the coils 60, 62 and 66 are covered with a cover (not shown).

At the time of assembly, the wire-shaped primary coil 60 is wound around the central winding portion 55a. The secondary coil (edgewise coils 62 and 66 are manufactured in a separate process and rotated to be screwed into the upper winding portion 55b and the lower winding portion 55c of the bobbin 10.
(Function and effect)
Even in the second embodiment, basically the same effects as in the first embodiment can be obtained. That is, vibration of the turn portion 63 of the upper secondary coil 62 is prevented by the protrusion 57, and vibration of the turn portion 67 of the lower secondary coil 66 is prevented by the protrusion 58. As a result, the contact between the turn portions 63 and 67 of each coil of the secondary coils 62 and 66 is prevented and the coating is protected, or the coating can be made of stone.

  In addition, the stress on the lead wire connecting portion is reduced during resonance. Further, only the ridges 57 and 58 are formed on the cylindrical portion 51 of the bobbin 50 in order to prevent vibration of the turn portions 63 and 67, and an increase in cost is suppressed to a minimum.

1 is an exploded perspective view showing a first embodiment of the present invention. It is a longitudinal cross-sectional view of 1st Example. It is a principal part longitudinal cross-sectional view of 2nd Example. It is a perspective view which shows a prior art example.

Explanation of symbols

10: Bobbin 11: Cylindrical part 12: Projection 20: Core member 21: Upper core 26: Lower core 30: Winding (edgewise coil) 31: Body part 32: Turn part 33: Clearance

Claims (8)

An insulating bobbin having a cylindrical portion;
A core member including a core portion inserted into the hollow hole of the cylindrical portion of the bobbin;
In the choke coil comprising a spirally wound winding located outside the outer peripheral surface of the cylindrical portion of the bobbin,
On the outer peripheral surface of the cylindrical portion, there is a movement preventing portion formed of a helical protrusion that fits into a helical gap between adjacent winding portions of the winding and prevents relative movement in the axial direction of each winding portion. A choke coil formed, wherein the protrusion is an incomplete thread at the tip of the cylindrical portion .   2. The choke coil according to claim 1, wherein the winding is an edgewise coil made of a strip-shaped rectangular copper wire. The helical ridge is a choke coil according to claim 1 or 2 are formed at the same pitch as the helical gap. An insulating bobbin having a cylindrical portion ;
A core member including a core portion inserted into the hollow hole of the cylindrical portion of the bobbin ;
In the manufacturing method of the choke coil comprising the spirally wound winding located outside the outer peripheral surface of the cylindrical portion of the bobbin ,
The outer circumferential surface of the cylindrical portion is fitted into a spiral gap between adjacent winding portions of the winding to prevent relative movement in the axial direction of each winding portion, and at the end of the cylindrical portion, an incomplete screw portion Forming a movement prevention part consisting of spiral ridges ,
The choke coil is manufactured by rotating the winding and screwing the spiral protrusion into the cylindrical portion of the bobbin by inserting the spiral protrusion between the winding gaps. A method for manufacturing a choke coil . An insulating bobbin having a cylindrical portion;
A core member including a core portion inserted into the hollow hole of the cylindrical portion of the bobbin;
A transformer comprising: a high-voltage winding spirally wound around the first shaft portion of the outer peripheral surface of the cylindrical portion of the bobbin; and a low-voltage winding spirally wound outside the second shaft portion;
The outer peripheral surface of the cylindrical portion is formed of a helical protrusion that fits in a helical gap between adjacent winding portions of the low-voltage winding and prevents relative movement in the axial direction of each low-voltage winding portion. A transformer characterized in that a movement preventing part is formed, and the protrusion is an incomplete threaded part at the tip of the cylindrical part .   The transformer according to claim 5, wherein the low-voltage winding is an edgewise coil made of a strip-shaped rectangular copper wire. The transformer according to claim 5 or 6 , wherein the spiral protrusions are formed at the same pitch as the spiral gap. An insulating bobbin having a cylindrical portion ;
A core member including a core portion inserted into the hollow hole of the cylindrical portion of the bobbin ;
Manufacture of a transformer comprising: a high voltage winding spirally wound around the first shaft portion of the outer peripheral surface of the cylindrical portion of the bobbin; and a low voltage winding spirally positioned outside the second shaft portion In the method
On the outer peripheral surface of the cylindrical portion, a helical gap between adjacent winding portions of the low-voltage winding is fitted to prevent relative movement in the axial direction of each winding portion, and an incomplete screw is formed at the tip of the cylindrical portion. Forming a movement prevention part consisting of spiral ridges that are part ,
The transformer is manufactured by rotating the low-voltage winding and screwing the helical protrusion into the cylindrical portion of the bobbin by inserting the spiral protrusion between the winding portions. A method of manufacturing a transformer .

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