JP2000036416A - Coil part - Google Patents

Abstract

PROBLEM TO BE SOLVED: To decrease the cost and to make it possible to form the thin configuration, by using a rectangular copper wire, making the narrow-width surface of this rectangular copper wire of the inner and outer surfaces of a coil, and providing the shape wherein the cross section is formed as the approximately elliptic shaped tube. SOLUTION: A coil 3 is formed by winding a rectangular copper wire 2. The cross- sectional shape of the coil 3 at the cutting surface perpendicular with the winding core of the coil is made to be approximately elliptic shape. The rectangular copper wire 2 is wound so that the narrow widths 2a and 2b of the wire become the inner and outer surfaces of the coil 3 (edgewise). The rectangular copper wire 2 is attached by covering the high-voltage output winding with the insulating cover, whose cross section forms the approximately elliptic-shaped tube. At both ends of this insulating cover, the terminal stages of the high-voltage output winding is formed integrally. The terminal which connects both ends of the high-voltage output winding is fixed to the terminal stages. Then, the low-voltage input winding comprising the rectangular copper wire 2 is wound from the center to the end side in the direction of the winding core of the insulating cover at the outer surface of the high-voltage output winding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil component such as an inductance element or a transformer using a thin rectangular copper wire.

[0002]

2. Description of the Related Art For example, in a high-voltage transformer for lighting a high-intensity discharge lamp or the like, a high voltage of 15 kV or more is generated in a high-voltage output winding, and a flowing current is relatively large. Therefore, it is necessary to increase the cross-sectional area of the wire used as much as possible and to ensure the withstand voltage.
As shown in (A) and (B), a multilayer winding 32 is provided around a resin-made cylindrical bobbin 30 via an insulating sheet 31.
In general, electrical specifications are ensured by a structure of winding a wire or a structure (not shown) of winding by using a divided bobbin.

On the other hand, if the windings are arranged in a single layer, the thickness can be reduced. However, if a thick wire is used to increase the current capacity, the entire coil becomes longer. For this reason, as shown in FIGS. 6C and 6D, a structure in which a thin wire 33 is wound around the bobbin 30 in a plurality of layers and connected in parallel has been devised.

Further, as shown in FIGS. 6 (E) and 6 (F),
For the structure in which the coil is wound in one layer, the flat copper wire 34
Is wound around the bobbin 30 such that the narrow surface is the inner circumference and the outer circumference.

[0005]

As shown in FIGS. 6A and 6B, in the structure in which the insulating sheet 31 is interposed in each layer, the manufacturing process is complicated, the manufacturing cost is high, and the thickness is low. It is a shape that is not suitable for conversion.

Further, as shown in FIGS. 6C and 6D,
In a structure in which a plurality of thin wires 33 are wound in a plurality of layers and the respective wires are connected in parallel to each other, the width of the coil changes due to a variation in the finished diameter of the wires 33, so that the bobbin 30 needs a margin in the core direction width. Becomes For this reason, when winding the second and subsequent layers, depending on the finished state of the lower layer winding, a step drop of the wire 33 due to winding disorder occurs, which causes a rare short circuit. In addition, since the same winding is wound in a plurality of layers, the winding time is extremely long, which causes an increase in cost. Also, it is difficult to reduce the thickness.

Further, as shown in FIGS. 6 (E) and 6 (F),
Even when the rectangular copper wire 34 is used, only a circular coil can be formed, and it is difficult to reduce the thickness.

The present invention has been made in view of the above problems, and has as its object to provide a coil component that can be made thinner than conventional transformers and inductors.

[0009]

According to a first aspect of the present invention, there is provided a coil component wherein a rectangular copper wire is used, and the narrow surface of the rectangular copper wire is the inner and outer peripheral surfaces of the coil, and the cross section is substantially oval. It is characterized by being formed in a shape.

As described above, by winding a rectangular copper wire so that its narrow surface becomes the inner circumference and the outer circumference, it is possible to increase the number of windings even with a single winding, and to secure the cross-sectional area and to increase the current. Can have capacity. In addition, by making the coil shape approximately elliptical, thinning can be achieved.

A coil component according to a second aspect is configured as a transformer, wherein the coil having a substantially elliptical cross section is a high-voltage output winding, and the outer periphery of the coil has a substantially elliptical cross section. And a low-voltage input winding is formed by winding a rectangular copper wire different from the rectangular copper wire on the outer surface of the insulating cover.

As described above, by using the thinned coil of claim 1 as a high-voltage output winding, a thinned transformer can be configured.

According to a third aspect of the present invention, in the coil component according to the second aspect, the low-voltage input winding is wound around an end of the insulating cover from a center in a winding core direction.

As described above, if the low-voltage input winding is wound around a portion of the insulating cover that is shifted to one side from the center, the side on which the low-voltage input winding is wound is set as the low-voltage side of the high-voltage output winding, thereby providing insulation. The above safety is improved.

According to a fourth aspect of the present invention, there is provided the coil component according to the second or third aspect, further comprising: a positioning guide for winding a low-voltage input winding and drawing out a terminal on the outer surface of the cylindrical insulating cover; Is formed so as to protrude outside the insulating cover, and has a groove for fitting a part of the low-voltage input winding in the middle of the positioning guide,
The low-voltage input winding has a horizontal groove provided in a cut shape from both ends of the low-voltage input winding of the positioning guide in the core direction, and a vertical groove formed from the horizontal groove to the tip of the positioning guide. The terminal is fitted and fixed in the horizontal groove and the vertical groove.

When such a positioning guide is provided, when winding the low-voltage input winding, a middle portion of the winding is guided, and the end portions at both ends are fitted into the cut-shaped lateral grooves, and then bent. By fitting along the flute,
It can be easily wound around the insulating cover and fixed.

According to a fifth aspect of the present invention, there is provided a coil component.
In any one of the above, a high-resistance ferrite core having a substantially oval rod shape having a cross-sectional shape matching the inner circumference of the coil is directly wound on the coil wound as the high-voltage output winding without using an insulator. At the same time, at both ends of the rod-shaped core,
A U-shaped ferrite core is provided so as to sandwich the core.

As described above, by adopting a structure in which the high-resistance ferrite core is directly inserted into the high-voltage output winding without using an insulator, the high-voltage output winding can be made thinner. Also,
As in the case of using U and U cores, a fixing means for fixing these cores in the winding core direction becomes unnecessary, and the size can be reduced accordingly.

[0019]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1A is an end view showing one embodiment of a coil component according to the present invention, and FIG.
FIG. 1C is an end view of the rectangular copper wire. Three
Is a coil formed by winding a rectangular copper wire 2. The coil 3 has a substantially oval cross-sectional shape in a cross section orthogonal to the winding core. The rectangular copper wire 2 is shown in FIG.
As shown in (1), the coils 3 are wound (edgewise) such that the narrow surfaces 2a and 2b are the inner and outer peripheral surfaces of the coil 3.

As described above, by using the rectangular copper wire 2 and winding the coil 3 so that the cross-sectional shape is substantially oval without using the coil bobbin, the thickness can be reduced. Also,
Since the rectangular copper wire 2 is used, the cross-sectional area of the wire can be secured, the number of windings can be secured, and the length in the core direction can be reduced.

FIGS. 2A, 2B, and 2C are a plan view, a front view, and a side view, respectively, showing an embodiment of a transformer according to the present invention using the above-described coil structure. FIG. 3A is a longitudinal sectional view of this transformer, and FIG.
FIG. 4 is a sectional view taken along line EE of FIG. In FIG. 3, 3
Is a high-voltage output winding composed of a coil in which the rectangular copper wire 2 is wound so as to have a substantially oval cross section as described above.

In FIGS. 2 and 3, reference numeral 4 denotes a cylindrical insulating cover made of resin and having a substantially oval cross section. The insulating cover 4 is attached so as to cover the high-voltage output winding 3. At both ends of the insulating cover 4, terminal blocks 4 a, 4
The terminals 5 and 6 for connecting both ends of the high-voltage output winding 3 are fixed to these terminal blocks 4a and 4b.

On the outer periphery of the high-voltage output winding 3, a low-voltage input winding 7 made of a flat copper wire is provided to improve insulation safety.
The insulating cover 4 is wound toward the end from the center in the winding core direction. That is, the low voltage input winding 7 side of the high voltage output winding 3 is the low voltage side of the high voltage output winding 3. The low-voltage input winding 7 is wound a plurality of times (twice in this example). In this example, the case where the input voltage is 380 V and the output voltage is 24 kV is shown.

On the outer periphery of the tubular insulating cover 4, a positioning guide 8 for winding the low-voltage input winding 7 and pulling out the terminal is integrally provided. The positioning guide 8
Is provided so as to protrude outside the insulating cover 4. In the middle part of the guide 8, one or more grooves 8a for fitting and positioning the middle part of the low-voltage input winding 7 are provided. As shown in FIG. 4, the roots at both ends of the guide 8 have cut-shaped lateral grooves 8 b and 8 c for fitting and positioning the ends of the low-voltage input winding 7, and the respective lateral grooves 8 b and 8 c Vertical grooves 8d, 8e are formed from the root of the guide 8 to the tip of the guide 8. These vertical grooves 8d and 8e are formed facing each other so that the tangential surfaces on the outer periphery of the insulating cover 4 are opened. The end of the low-voltage input winding 7 is easily fixed by first fitting it into the lateral grooves 8b and 8c as shown by the arrow X and then bending it so as to fit into the vertical grooves 8d and 8e as shown by the arrow Y. .

In FIG. 3A, reference numeral 9 denotes a rod core inserted into a coil wound as the high-voltage output winding 3. The core 9 of the present example has a substantially elliptical cross section slightly smaller than the inner peripheral shape of the coil. By using a high-resistance ferrite core as the core 9, the core 9 can be directly incorporated into the high-voltage output winding 3 without using an insulator. 10 is at both ends of a rod-shaped core so as to sandwich the core,
It is a U-shaped ferrite core which is attached via an insulating material 11 and forms a magnetic circuit.

As shown in FIG. 2, the legs 10a, 10a of the U-shaped ferrite core 10 are provided at both ends of the insulating cover 4.
A pair of holding pieces 4c for fixing the holding member b are provided at both ends of the insulating cover 4.

The insulating cover 4 and the core 10 are fixed with an adhesive (not shown). More generally, the terminals 7a and 7b of the low-voltage input winding 7 and the terminals 5 and 7 of the high-voltage output winding 3 are connected. Portions other than 6 are molded with a resin (not shown).

FIG. 5 (A) is a sectional view showing another embodiment of the present invention, and FIG. 5 (B) is a sectional view taken along line FF of FIG. 5 (A). Instead of the U-shaped core 10, two U-shaped high-resistance ferrite cores 13, 1
3 are combined via an insulating material 14, and the other structure is as described above. In this case, means (not shown) for fixing the ferrite cores 13 and 13 is required.

When the embodiment shown in FIG. 5 is compared with the embodiment shown in FIG. 3, the rod-shaped core 9 and the U-shaped core 10 are combined as shown in FIG. There is no need for a fixing means for the cores 13, 13, and there is an advantage that the overall shape can be reduced in size.

In the present invention, the substantially elliptical shape which is the cross-sectional shape of the coil includes, for example, an elliptical shape and an oval shape approximating an elliptical shape.

[0031]

According to the first aspect of the present invention, the narrow surface of the rectangular copper wire is formed in a cylindrical shape having the inner and outer peripheral surfaces of the coil and the cross section is substantially oblong. In addition, the current capacity can be secured by securing the cross-sectional area, which enables downsizing and simplification of the manufacturing process, and achieves a thinner shape by making the coil shape approximately oblong. it can.

According to the second aspect, the coil having the structure of the first aspect is a high-voltage output winding, and the outer periphery of the coil is covered with a cylindrical insulating cover, and the outer surface of the insulating cover is different from the flat copper wire. The low-voltage input winding is obtained by winding the flat copper wire of the above, so that a thinner transformer can be configured.

According to the third aspect, in the second aspect, the low-voltage input winding is wound on the end side from the center in the longitudinal direction of the insulating cover. By setting the low-voltage side of the output winding, the creepage distance between the high-voltage side of the high-voltage output winding and the low-voltage input winding can be increased, thereby improving insulation safety.

According to a fourth aspect, in the second or third aspect, a positioning guide for winding a low-voltage input winding and drawing out a terminal is provided on an outer surface of the cylindrical insulating cover. The positioning guide has a groove formed in a middle portion of the positioning guide so as to fit an intermediate portion of the low-voltage input winding, and both ends of the positioning guide in the core direction of the low-voltage input winding. Each having a transverse groove provided in a notch shape, and having a vertical groove formed from the transverse groove to the tip of the positioning guide,
Since the low-voltage input winding terminal is fixed by being fitted into the lateral groove and the vertical groove, when winding the low-voltage input winding,
While the middle part of the winding is guided, the ends at both ends are fitted into the cut-shaped lateral groove, then bent and fitted along the vertical groove, so that it can be easily wound around the insulating cover and fixed. it can.

According to a fifth aspect, in any one of the second to fourth aspects, the coil wound as the high-voltage output winding is provided with a substantially elliptical rod shape having a sectional shape matching the inner circumference of the coil. A high-resistance ferrite core is directly incorporated without an insulator, and a U-shaped ferrite core is provided at both ends of the rod-shaped core so as to sandwich the core. By inserting a high-resistance ferrite core directly without using an insulator, the high-voltage output winding can be made thinner. Further, unlike U and U cores, a fixing means for fixing these cores in the winding core direction is not required, and the size can be reduced accordingly.

[Brief description of the drawings]

FIG. 1A is an end view showing an embodiment of a coil component according to the present invention, FIG. 1B is a cross-sectional view taken along the line DD, and FIG. 1C is an end view showing an example of a rectangular copper wire used in the present invention. FIG.

FIGS. 2A, 2B, and 2C are a plan view, a front view, and a side view, respectively, illustrating an embodiment of a transformer according to the present invention configured using the coil structure.

3A is a longitudinal sectional view of the transformer, and FIG. 3B is a sectional view taken along line EE of FIG. 3A.

FIG. 4 is a perspective view showing a positioning guide in the embodiment of FIGS. 2 and 3;

5A is a longitudinal sectional view of a transformer according to another embodiment of the present invention, and FIG. 5B is a sectional view taken along line FF of FIG.

6A is an end view showing an example of a conventional coil component, FIG. 6B is a cross-sectional view thereof, FIG. 6C is an end view showing another example of the conventional coil component, and FIG. FIG. 1E is an end view showing another example of a conventional coil component, and FIG. 1F is a sectional view thereof.

[Explanation of symbols]

1: bobbin, 2: rectangular copper wire, 3: coil (high-voltage output winding), 4: insulating cover, 5, 6: terminal, 7: low-voltage input winding, 8: positioning guide, 8a: groove, 8b, 8c: horizontal groove, 8d, 8e: vertical groove, 9: rod-shaped core, 10: U-shaped core, 11, 14: insulating material, 13: U-shaped core

 ────────────────────────────────────────────────── ─── Continued on the front page F term (reference) 5E043 AA02 AB03 AB04 BA01 EA01 EA05 EA06 EB01 EB02 5E044 AD06 CA03 CA04 CA08 CB08 DA01 DA03

Claims (5)

[Claims] 1. A coil component using a rectangular copper wire, wherein the narrow surface of the rectangular copper wire is formed into a cylindrical shape having inner and outer peripheral surfaces of a coil and a substantially elliptical cross section. 2. A coil having a substantially elliptical cross section as a high-voltage output winding, wherein the outer periphery of the coil is covered by a cylindrical insulating cover having a substantially elliptical cross section. A coil component, wherein a low-voltage input winding is formed by winding a flat copper wire different from the flat copper wire. 3. The coil component according to claim 2, wherein the low-voltage input winding is wound on an end side of a center of the insulating cover in a core direction. 4. The insulating guide according to claim 2, wherein a positioning guide for winding a low-voltage input winding and for pulling out a terminal is provided on an outer surface of the cylindrical insulating cover. The positioning guide has a groove at an intermediate portion of the positioning guide, into which a part of the low-voltage input winding is fitted, and cuts from both ends of the low-voltage input winding of the positioning guide in the core direction. A coil having a transverse groove provided and a longitudinal groove formed from the transverse groove to the tip of the positioning guide, wherein the low-voltage input winding terminal is fitted and fixed in the transverse groove and the longitudinal groove. parts. 5. The high-resistance ferrite core according to claim 2, wherein the coil wound as the high-voltage output winding has a substantially elliptical rod-like shape whose cross-sectional shape matches the inner circumference of the coil. And a coil-shaped ferrite core is provided at both ends of the rod-shaped core so as to sandwich the core.