JP4290489B2 - Coil device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a coil device that constitutes a reactor, a transformer, and the like in various AC devices.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a coil core used for a reactor, a transformer, or the like has widely adopted a winding core that has excellent magnetic characteristics and high mass productivity.
Moreover, in the winding core used for the reactor, a magnetic gap portion is provided in the magnetic path to stabilize the DC superposition characteristics, and further, the direct current is dispersed by dispersing the magnetic gap portion in a plurality of locations. Further stabilization of superimposition characteristics, suppression of leakage magnetic flux from the magnetic gap, reduction of eddy current loss due to leakage magnetic flux, and the like are achieved.
[0003]
FIG. 12 shows a conventional coil device for a reactor. In the coil device, a plurality of magnetic gap layers (41) are interposed in the magnetic path of the core (10), surround the magnetic path, and the coil (56) is wound around the bobbin (55). A coil assembly (57) is mounted (see Patent Documents 1 and 2).
[0004]
8-11 represents the manufacturing method of the said coil apparatus.
As shown in FIG. 8, after a metal strip is wound to produce an annular wound core member (22), the wound core member (22) is cut into a plurality of cutting lines BB indicated by broken lines in the drawing. As shown in FIG. 9, a pair of C-shaped split core pieces (23) (23) and a plurality of I-shaped (cuboid) split core pieces (24) (24) ( 24) and get.
[0005]
Next, as shown in FIG. 10, between the opposing surfaces of the C-shaped divided core piece (23) and the I-shaped divided core piece (24) and between the opposing surfaces of the I-shaped divided core pieces (24), A plurality of I-shaped divided core pieces (24) are joined to one C-shaped divided core piece (23) with a magnetic gap layer (41) interposed therebetween to obtain a U-shaped core block.
Thereafter, as shown in FIG. 11, two coil assemblies (57) formed by winding a coil (56) around a bobbin (55) are mounted on the U-shaped core block, and then the U-shaped core block is moved to the U-shaped core block as shown in FIG. The other C-shaped split core piece (23) is joined to the U-shaped core block to complete the coil device.
In the coil device shown in FIG. 12, the integrated structure of the core (10) is reinforced by the fastening band (6).
[0006]
13 to 15 show a winding state and a connection state of a pair of coil assemblies (57a) and (57b) constituting the coil device.
In one coil assembly (57a) shown in FIG. 13, the winding start end portion (58a) and the winding end end portion (59a) of the coil (56a) comprising two layers are respectively locked to the flange portions of the bobbin (55a). Has been. Similarly, in the other coil assembly (57b) shown in FIG. 14, the winding start end portion (58b) and the winding end end portion (59b) of the two-layer coil (56b) are respectively located on the flange portions of the bobbin (55b). It is locked.
Then, both coil assemblies (57a) and (57b) are arranged adjacent to each other as shown in FIG. 15, and the winding end (59a) of the coil (56a) of one coil assembly (57a) and the other coil assembly ( The winding start end portion (58b) of the coil (56b) of 57b) is connected to each other, and the connection portion (50) is insulated.
[0007]
[Patent Document 1]
JP 2001-68352 A [Patent Document 2]
JP 2001-167949 A
[Problems to be solved by the invention]
However, in the above-described conventional coil device, since the structure in which the core (10) is integrated by the fastening band (6) as shown in FIG. 12 is adopted, the I-shaped divided core constituting the core (10) is adopted. When the piece (24) is tightened by the fastening band (6), it receives a large compressive force in the magnetic path direction. As a result, there is a problem that the desired inductance characteristics cannot be obtained.
Further, as shown in FIG. 10, since it is necessary to join a plurality of core pieces (23) and (24) to one C-shaped divided core piece (23) via a magnetic gap layer (41), the assembly process is reduced. There was a complicated problem.
[0009]
Accordingly, an object of the present invention is to provide a coil device having a desired inductance characteristic in a coil device having a magnetic gap portion between a plurality of core pieces and having a simpler assembly process than the conventional one. .
[0010]
[Means for solving the problems]
The coil device according to the present invention penetrates through a cylindrical bobbin (8), a coil (7) wound around the outer peripheral surface of the bobbin (8), and an internal space (80) of the bobbin (8). The core (1) is provided between a pair of C-shaped core pieces (2) (2) and both C-shaped core pieces (2) (2). It consists of at least one intervening rectangular parallelepiped core piece (3).
The internal space (80) of the bobbin (8) has at least one central space A in which the rectangular parallelepiped core piece (3) should be accommodated, and a pair of C-shaped core pieces (2 ) (2) has two side spaces B and B in which the end portions are to be accommodated.
A spacer having a predetermined thickness is interposed between the central space A and each side space B of the bobbin (8) to separate the two spaces by a predetermined distance. An opening (87) for inserting the rectangular parallelepiped core piece (3) into the central space A is formed on the side wall of the bobbin (8).
[0011]
In the coil device of the present invention, the spacer formed between the central space A and the side space B of the bobbin (8) is between the rectangular parallelepiped core piece (3) and the C-shaped core piece (2). The both core pieces (3) and (2) are spaced apart by a distance corresponding to the thickness of the spacer. As a result, a magnetic gap portion corresponding to the thickness is formed between the core pieces (3) and (2). Here, even if a pinching force acts on the pair of C-shaped core pieces (2) and (2), the pinching pressure is received by the ribs (85) and (86) of the bobbin (8), and the rectangular parallelepiped core piece ( It does not act on 3).
[0012]
In the assembling process of the coil device, the rectangular parallelepiped core piece (3) is inserted into the central space A from the opening (87) of the bobbin (8), and then the coil (7) around the bobbin (8). Wrap. The C-shaped core piece (2) has its end inserted into the side space B of the bobbin (8) and is fixed to the bobbin (8) with an adhesive, for example.
[0013]
In a specific configuration, the pair of C-shaped core pieces (2) is formed by dividing the annular wound core member (21) into two parts. The rectangular parallelepiped core piece (3) is formed by laminating a plurality of iron plate pieces (31).
According to this specific configuration, it is possible to form the C-shaped core piece (2) and the rectangular parallelepiped core piece (3) from materials having different characteristics, thereby obtaining a composite characteristic by combining the two materials. I can do it.
[0014]
In another specific configuration, the side space B of the bobbin (8) is filled with an adhesive (9) surrounding the end of the C-shaped core piece (2), and the adhesive (9) A C-shaped core piece (2) is fixed to the bobbin (8).
According to this specific configuration, in the assembly process of the coil device, the side space B of the bobbin (8) is filled with the adhesive (9), and then the C-shaped core piece (2) is placed in the side space B. By inserting the end portion, the adhesive (9) flows backward from the back of the side space to the opening side, and covers the end portion of the C-shaped core piece (2) with a wide area. As a result, the bonding area between the C-shaped core piece (2) and the bobbin (8) is increased, and a larger bonding force can be obtained.
The adhesive (9) is also filled in the gap between the central space A and the side space B, whereby the C-shaped core piece (2) and the rectangular parallelepiped core piece (3) are fixed to each other.
[0015]
【The invention's effect】
According to the coil device according to the present invention, since an extra external force is not applied to the rectangular parallelepiped core piece (3), desired inductance characteristics can be obtained. Further, by incorporating the C-shaped core piece (2) and the rectangular parallelepiped core piece (3) into the bobbin (8), these core pieces are integrated and a magnetic gap is formed between the core pieces. Therefore, there is no need for a step of joining a plurality of core pieces to each other via a magnetic gap layer as in the prior art, which makes the assembly process easier than in the prior art.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
As shown in FIG. 1, the coil device according to the present invention is configured by mounting a pair of coil assemblies (5) and (5) on an annular core (1), and each coil assembly (5) has a rectangular tube shape. It consists of a bobbin (8) and a coil (7) wound around the outer peripheral surface of the bobbin (8). The core (1) extends annularly through the two bobbins (8), (8).
[0017]
The two coils (7) and (7) constituting the two coil assemblies (5) and (5) are formed by winding one conductive wire, and both the coils (7) and (7) are connected to the connecting wire (72 ) Are connected to each other. From both the coils (7) and (7), a winding start end portion (71) and a winding end end portion (73) of the conducting wire are drawn out.
[0018]
As shown in FIG. 2, the core (1) is composed of a pair of C-shaped core pieces (2) (2) and two rectangular parallelepiped core pieces interposed between the two C-shaped core pieces (2) (2). (3) and (3). Note that FIG. 2 is a partially broken plan view of the coil device, but the cross section shown in the drawing is drawn as one of the coil assemblies (5) cut along a vertical plane for convenience.
[0019]
In the production of the pair of C-shaped core pieces (2) and (2), as shown in FIG. 4 (a), an annular wound core member (21 ) Is cut along a single cutting line AA indicated by a broken line in the drawing, thereby forming a pair of left and right C-characters as shown in FIG. The segmented core pieces (2) and (2) are obtained.
The rectangular parallelepiped core piece (3) is formed by laminating a plurality of rectangular steel plate pieces (31) made of silicon steel plate or amorphous material as shown in FIG.
[0020]
The bobbin (8) is an integrally molded product made of a synthetic resin, and as shown in FIG. 3, a rectangular tube-shaped body (88) and a frame protruding from both ends of the body (88). The inner space (80) of the bobbin (8) includes a central space A in which the rectangular parallelepiped core piece (3) is accommodated, and both sides of the central space A. It has two side spaces B and B which are formed and should accommodate the ends of the pair of C-shaped core pieces.
[0021]
Two upper and lower wall surfaces facing the internal space (80) of the bobbin (8) have two upper and lower ribs (85) (85) having a predetermined thickness between the central space A and one side space B. ) Projectingly, the two spaces are separated by the ribs (85) and (85), and the upper and lower ribs (86) having a predetermined thickness are provided between the central space A and the other side space B. ) (86) is projected, and both spaces are separated by the ribs (86) (86).
[0022]
In addition, a rectangular opening (87) for inserting the rectangular parallelepiped core piece (3) into the central space A is formed on the upper side wall constituting the body portion (88) of the bobbin (8).
Furthermore, one hook part (81) of the bobbin (8) has two engagements for locking the coil winding as will be described later on one of the four end faces forming a rectangular outer shape. Stop grooves (83) and (84) are recessed.
[0023]
As shown in FIG. 2, each bobbin (8) accommodates a rectangular parallelepiped core piece (3) and a pair of C-shaped core pieces (2) (on both sides of the rectangular parallelepiped core piece (3)). 2) is housed between the end face of the rectangular parallelepiped core piece (3) and the end face of the C-shaped core piece (2) according to the thickness of the ribs (85) and (86). A gap G is formed. As a result, four magnetic gap portions are interposed in the magnetic path of the core (1).
[0024]
The two lateral spaces of each bobbin (8) are filled with an adhesive (9) surrounding the end of the C-shaped core piece (2), and the C-shaped core is filled with the adhesive (9). The piece (2) is fixed to the bobbin (8).
The adhesive (9) is also filled in a gap formed between the end face of the rectangular parallelepiped core piece (3) and the end face of the C-shaped core piece (2), whereby the rectangular parallelepiped core piece ( 3) and the C-shaped core piece (2) are connected and fixed to each other.
[0025]
In the assembly process of the coil device, a rectangular parallelepiped core piece (3) is inserted into each bobbin (8) as shown in FIG. 3, and then both bobbins (8a) and (8b) are connected in series as shown in FIG. 6 (a). Arranged in a positional relationship, winding is applied to the outer peripheral surfaces of both bobbins (8a) and (8b).
In the winding process, first, the winding start end (71) of the conducting wire is locked in one locking groove (83a) of the left bobbin (8a), and the bobbin (8a) is moved from the right side to the left side. After the sequential winding is performed, the winding is folded back, and the winding is performed sequentially from the left side to the right side, and the conducting wire is locked in the other locking groove (84a) of the bobbin (8a).
[0026]
Subsequently, the connecting wire (72) that has passed through the locking groove (84a) is locked to one locking groove (83b) of the right bobbin (8b), and in this state, the left side of the bobbin (8b) After winding sequentially from the right side to the right side, it is folded and wound sequentially from the right side to the left side, and the conducting wire is locked to the other locking groove (84b) of the bobbin (8b). Pull out the winding end (73) from (84b). The length of the crossover (72) is the minimum necessary.
[0027]
Next, as shown by the arrows in FIG. 6A, the left bobbin 8a is rotated 180 degrees with respect to the right bobbin 8b, and both bobbins 8a and 8b are moved as shown in FIG. 8b) are arranged in a parallel positional relationship where the buttocks contact each other.
Along with this, the connecting wire (72) extending from one coil (7a) to the other coil (7b) is bent in an arc shape, and the adjacent locking grooves (84a) of both bobbins (8a) (8b) (83b) is stretched at the shortest distance. Therefore, the crossover (72) does not interfere with other adjacent parts.
Further, along with the juxtaposition of both bobbins (8a) and (8b), tension is applied to the connecting wire (72) locked to the two locking grooves (84a) and (83b), and both bobbins (8a ) (8b) are fastened to each other, and the relative positional relationship between the bobbins (8a) and (8b) is defined.
[0028]
After the winding process of the coils (7a) and (7b) to both bobbins (8a) and (8b), as shown in FIG. 7, a pair of C-shaped core pieces (2) and (2) (2 ) And the pair of C-shaped core pieces (2) and (2) are fixed to both bobbins (8a) and (8b).
At this time, prior to the insertion of the C-shaped core piece (2), an appropriate amount of adhesive is filled in the side space of the bobbin (8), and the end of the C-shaped core piece (2) is filled with the adhesive. The part is fixed to the bobbin (8). The adhesive filled in the side space of the bobbin (8) flows backward from the back of the side space to the opening side with the insertion of the C-shaped core piece (2), and as shown in FIG. The end of the letter-shaped core piece (2) is covered with a large area. As a result, the C-shaped core piece (2) and the bobbin (8) are bonded in a large area, and a larger adhesive force can be obtained. .
Further, the adhesive (9) filled in the side space of the bobbin (8) is also filled in a region to be a magnetic gap between the C-shaped core piece (2) and the rectangular parallelepiped core piece (3). As a result, the C-shaped core piece (2) and the rectangular parallelepiped core piece (3) are connected and fixed to each other.
[0029]
According to the coil device manufactured in this way, an extraneous external force is not applied to the rectangular parallelepiped core piece (3), so that an intended inductance characteristic can be obtained. Further, by incorporating the C-shaped core piece (2) and the rectangular parallelepiped core piece (3) into the bobbin (8), these core pieces are integrated and a magnetic gap is formed between the core pieces. Therefore, there is no need for a step of joining a plurality of core pieces to each other via a magnetic gap layer as in the prior art, thereby making the assembly process easier than in the prior art.
[0030]
In addition, the rectangular parallelepiped core piece (3) and the C-shaped core piece (2) can be produced using materials having different characteristics (for example, silicon steel plate, amorphous material, etc.), so that a combination of a plurality of materials is combined. Characteristics can be obtained.
[0031]
In the coil device, two coils (7) and (7) constituting a pair of coil assemblies (5) and (5) are formed by winding one conductive wire, and both coils (7) and (7) are formed. Are connected via a crossover wire (72), and the crossover wire (72) is stretched between the two bobbins (8) and (8) at the shortest distance, so that the conventional coil shown in FIG. It is not necessary to connect the winding end portion (59a) of one coil (56a) and the winding start end portion (58b) of the other coil (56b) to each other as in the case of an apparatus. Since it does not need to take a long length, it does not interfere with other parts to be arranged around.
[0032]
Furthermore, according to the method for manufacturing a coil device according to the present invention, two coils (7) and (7) are formed by continuously winding one conductive wire. Compared with the conventional manufacturing method wound around, the manufacturing is simple. However, since it is not necessary to connect the ends of the two coils (7) and (7) to each other, there is no need to solder or insulate the connection part, which was necessary in the past, which greatly reduces the number of assembly steps. Is done.
[0033]
In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, it is not limited to the configuration in which the ribs (85) and (86) project from the two upper and lower wall surfaces facing the inner space (80) of the bobbin (8), and the inner space (80) of the bobbin (8) is surrounded by 4 It is also possible to employ a configuration in which ribs are provided so as to project on all of the two wall surfaces, or a configuration in which a flat partition wall that completely partitions the central space and the side space is formed.
Further, the number of rectangular parallelepiped core pieces (3) to be interposed between the pair of C-shaped core pieces (2) and (2) is not limited to two, and may be one or more than two. It is also possible to form more magnetic gap portions by interposing the rectangular parallelepiped core piece (3).
[Brief description of the drawings]
FIG. 1 is a perspective view of a coil device according to the present invention.
FIG. 2 is a partially broken plan view of the coil device.
FIG. 3 is a perspective view of a bobbin.
FIG. 4 is a diagram showing a manufacturing process of a C-shaped core piece.
FIG. 5 is a diagram illustrating a manufacturing process of a rectangular parallelepiped core piece.
FIG. 6 is a plan view for explaining a winding method for two bobbins.
FIG. 7 is a plan view showing a process of inserting a C-shaped core piece into the bobbin.
FIG. 8 is a plan view of a wound core member used for manufacturing a conventional coil device.
FIG. 9 is a view showing a process of dividing the wound core member.
FIG. 10 is a diagram showing a process of joining a plurality of I-shaped divided core pieces to one C-shaped divided core piece.
FIG. 11 is a diagram illustrating a process of mounting a coil assembly.
FIG. 12 is a partially broken plan view of a conventional coil device.
FIG. 13 is a perspective view of one coil assembly constituting a conventional coil device.
FIG. 14 is a perspective view of the other coil assembly constituting the conventional coil device.
FIG. 15 is a plan view showing a state where two coil assemblies are connected to each other.
[Explanation of symbols]
(1) Core
(2) C-shaped core piece
(3) Cuboid core piece
(5) Coil assembly
(7) Coil
(71) End of winding
(72) Crossover
(73) End of winding
(8) Bobbin
(81) Buttocks
(82) Buttocks
(83) Locking groove
(84) Locking groove
(85) Ribs
(86) Ribs
(87) Opening
(9) Adhesive

Claims (4)

A cylindrical bobbin (8), a coil (7) wound around the outer peripheral surface of the bobbin (8), and an annular core (through the inner space (80) of the bobbin (8)) 1), the core (1) includes at least one interposed between the pair of C-shaped core pieces (2) and (2) and both the C-shaped core pieces (2) and (2). The inner space (80) of the bobbin (8) includes at least one central space A in which the rectangular parallelepiped core piece (3) is to be accommodated, and both sides of the central space A. And have two side spaces B and B that should accommodate the ends of the pair of C-shaped core pieces (2) and (2). Between the central space A and each side space B, 1 or a plurality of ribs protruding from the inner surface of the bobbin (8) by integral molding of the resin are interposed, and a predetermined magnetic gap is formed between the core pieces (2) and (3) by the thickness of the ribs. On the side wall of the bobbin (8) The coil device is characterized in that an opening (87) for inserting the rectangular parallelepiped core piece (3) into the central space A is formed. The coil device according to claim 1 , wherein the pair of C-shaped core pieces (2) are formed by dividing an annular wound core member (21) into two parts. The coil device according to claim 1 or 2 , wherein the rectangular parallelepiped core piece (3) is formed by laminating a plurality of iron plate pieces (31). The side space B of the bobbin (8) is filled with the adhesive (9) so as to surround the end of the C-shaped core piece (2), and the C-shaped core piece (2) is filled with the adhesive (9). The coil device according to any one of claims 1 to 3 , wherein the coil device is fixed to the bobbin (8).

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