JP2000114081A - Manufacture of separate type transformer core - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a separate type transformer core wherein a coil is easily provided to a core with no gap between the core and the coil, for improved transmission efficiency in electric power, etc. SOLUTION: A coil 2 formed into a specified shape is molded using a first molten synthetic resin 3 which comprises a soft magnetic material, molding to a desired shape which is used as a core 1. Related to the coil 2, an electric wire such as a coil wherein a polyamide group fusing coat is over-coated on a polyurethane group insulating coat is wound by such times as required for a transformation application. The coil is molded into a ring shape, and the shape is kept by a bonding agent, etc. Related to the soft magnetic resin 3, a soft magnetic ferrite powder such as an Ni-Zn group ferrite and Mn-Zn group ferrite, (maximum particle size is 300 μm or smaller, and, a maximum particle size 100 μm or less is preferred while average particle size 3.8 μm is preferred as well) is mixed with such synthetic resin such as nylon and polyphenylene sulfide (PPS) by a specified amount (for example, the content of soft magnetic material is 50-90 wt.%), with a relative permeability of about 3-20.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a method for manufacturing a separated transformer core.

[0002]

2. Description of the Related Art A separation type transformer has a core having a coil and a corresponding coil arranged opposite to each other. Electromagnetic coupling between the corresponding coils allows electric power and electric signals to be transmitted between the two coils in a non-contact manner. Transmit. Such a separation type transformer is also applied to a rotary transformer in which each core rotates relative to each other. For example, the transformer is mounted on a steering device of an automobile and provided on a steering side which rotates from a steering column side fixed to a vehicle body. It can be used as transmission means for transmitting operating power and the like to the detonator.

[0003] In the core of such a separation type transformer, for example, a coil groove extending in the circumferential direction is formed on one surface of a disk-shaped core, and a coil formed of a ring-shaped winding is inserted into the coil groove. Alternatively, a general manufacturing method is to drop the winding along the peripheral surface of the coil groove and form a coil corresponding to the groove shape in multiple layers.

[0004]

When the molded coil is inserted into the coil groove in the production of the core, the coil is not inserted unless the coil groove has a certain allowable value with respect to the coil width. Cannot be inserted into coil groove.
As a result, in the assembled separation type transformer, a small gap is formed between the core and the coil, and the leakage magnetic flux increases between the opposing coils and the magnetic coupling is weakened. Efficiency deteriorates.

In order to avoid such inconveniences, it is necessary to increase the coil forming accuracy and the coil groove forming accuracy, and to make the gap between the coil and the core as small as possible.
An advanced insertion technique for inserting a coil into a coil groove is required. Also, when dropping the winding along the coil groove,
A gap is required to drop the end of the winding, and the transmission efficiency deteriorates as in the case where the coil is inserted into the coil groove.

[0006] The present invention has been made in view of the above points, and a coil can be easily provided on a core, there is no gap between the core and the coil, and transmission efficiency of electric power and the like can be improved. An object of the present invention is to provide a method for manufacturing a separated transformer core.

[0007]

In order to achieve the above object, in a method for manufacturing a separation type transformer core according to the present invention, a coil formed into a predetermined shape is formed by melting a first synthetic resin containing a soft magnetic material. Thus, it is configured to mold into a desired shape. Preferably, after winding an electric wire around a bobbin having soft magnetism to form a coil of a predetermined shape,
It is molded into a desired shape by molding with the molten first synthetic resin.

Preferably, the bobbin is made of a second synthetic resin containing a soft magnetic material. More preferably, the bobbin is made of soft magnetic sintered ferrite. Preferably, a bobbin provided at the end of the electric wire, in which the connecting portion connected to the external electric wire is integrated or wound and extends, is used. Preferably, a coil having a predetermined shape is formed by winding an electric wire around each of a plurality of bobbins having different radii, and is molded into a desired shape by molding with the molten first synthetic resin.

More preferably, a plurality of coils are wound at a predetermined interval in the axial direction of the bobbin to form a predetermined shape, and then molded with the molten first synthetic resin to form a desired shape. Preferably, after the molten first synthetic resin containing the soft magnetic material is molded on either the outer peripheral side or the inner peripheral side of the coil formed into a predetermined shape, the inner peripheral side or the outer peripheral side is further molded. On the other side, the first synthetic resin containing a soft magnetic material is molded.

[0010] Preferably, the first material has soft magnetism.
An electric wire is wound around a bobbin provided with a concavo-convex structure for increasing the contact area with the synthetic resin, and a coil having a predetermined shape is formed. Then, the coil is molded with the molten first synthetic resin to form a desired shape. More preferably, at the time of molding, the mounting portion is integrally formed outside. Here, soft magnetism used in the present specification refers to a property in which remanence is extremely small.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of a method for manufacturing a separated transformer core according to the present invention will be described below in detail with reference to FIGS. As shown in FIG. 1, a separated transformer core (hereinafter, simply referred to as a “core”) 1 is formed by molding a coil 2 into a soft magnetic resin 3 to form a ring shape. It is exposed on the inner circumference.

The coil 2 is formed by winding an electric wire such as a winding obtained by overcoating a polyurethane-based insulating film with a polyamide-based fused film over a number of turns as required for a transformer application, and forming it into a ring shape. The shape is held by an adhesive or the like. The soft magnetic resin 3 is, for example, a soft magnetic ferrite powder (maximum particle diameter 300 μm or less, preferably maximum particle diameter 100 μm or less, more preferably average particle diameter 3. 8μ
m) is nylon or polyphenylene sulfide (PPS)
A predetermined amount (for example, the content of the soft magnetic material is 50 to 90% by weight) is mixed in the synthetic resin such as the above, and the relative magnetic permeability is about 3 to 20.

The core 1 configured as described above is manufactured as follows. First, as shown in FIG. 2, the coil 2 is placed in the molding dies 5 and 6 of an injection molding machine (not shown), and the soft magnetic resin 3 melted from the runner 5a of the molding die 5 is placed in the annular cavity C. At high pressure. This allows
The soft magnetic resin 3 fills the entire cavity C.

After the soft magnetic resin 3 has cooled to a predetermined temperature, the molds 5 and 6 are opened and the core 1 is taken out. Therefore, since the coil 1 is molded with the soft magnetic resin 3 in which the coil 2 is melted, the coil 2 can be provided very easily, and no gap is generated between the core 1 and the coil 2.
Therefore, the separation type transformer using the core 1 can improve the transmission efficiency of electric power and the like.

Here, the coil may be formed by winding an electric wire around a bobbin. An embodiment of a core using such a coil will be described with reference to FIGS.
The core 10 has a coil 11 and a soft magnetic resin 12, as shown in FIG. The coil 11 is a bobbin 11a formed by winding a wire 11b such as a winding in which a polyamide insulating coating is overcoated on a polyurethane insulating coating, in a required number of turns corresponding to a transformer use, and the wire 11b retains its shape. For this purpose, they may be bonded with an adhesive or the like. Here, the bobbin 11 a is formed in a ring shape from a second synthetic resin having the same composition as the soft magnetic resin 3.

The soft magnetic resin 12 is made of a first synthetic resin having the same composition as the soft magnetic resin 3. In the present embodiment, for example, 85% by weight of ferrite powder composed of Mn-Zn is added to nylon 12. The compound having a soft magnetism having a relative magnetic permeability of 10 is used. The core 10 configured as described above is manufactured as follows.

First, as shown in FIG. 4, a coil 11 is formed by winding a wire 11b around a bobbin 11a by a predetermined number of turns. Next, as shown in FIG. 5, the coil 11 is disposed in the molding dies 13 and 14 of an injection molding machine (not shown), and the soft magnetic resin 12 melted from the runner 13a of the molding die 13 is formed into an annular cavity C. Is injected at high pressure. Thereby, the soft magnetic resin 1
2 fills the entire cavity C.

After the soft magnetic resin 12 has cooled to a predetermined temperature, the molds 13 and 14 are opened and the core 10 is taken out. Therefore, the core 10 is, like the core 1, the coil 11
Can be provided very easily inside, and the core 1
No separation occurs between the coil 0 and the coil 11, and the separation type transformer using the core 10 can improve the transmission efficiency of electric power and the like. Further, the electric wire 11b is securely held on the bobbin 11a, so that deformation at the time of molding, that is, deformation of the coil 11 can be suppressed.

Here, the core having a plurality of coils, in the case of a core for an opposing separated type transformer shown in FIG. 6, is formed by winding electric wires 15b to 17b around a plurality of bobbins 15a to 17a having different radii. Coil of predetermined shape 15-17
And these coils 15 to 17 are concentrically arranged in molding dies 18 and 19 of an injection molding machine (not shown), and molten soft magnetic resin is injected into the annular cavity C from the runner 18 a of the molding die 18. To manufacture.

At this time, the bobbins 15a to 17a may be sequentially molded into a ring using the same composition as the soft magnetic resin 3, but the injection pressure of the soft magnetic resin injected into the cavity C is reduced. If it is necessary to set it high and there is a concern about bobbin deformation, high strength and heat resistance commonly used in magnetic circuits to prevent deformation due to the injection pressure of soft magnetic resin when molding the core Exhibiting soft magnetic properties such as Ni—Zn ferrite (Fe ₂
O ₃ with ZnO, NiO, etc. added), Mg-Zn
System ferrite (MgO to Fe ₂ O _3, those that have been added or ZnO), or the Mn-Zn ferrite (Fe ₂ O ₃ Mn
A soft magnetic ferrite sintered body formed into a ring shape by mixing a binder agent with O or MnCO ₃ , ZnO or the like) and sintering using a mold may be used.

On the other hand, the core shown in FIG. 6 is for the opposing separation type transformer, but the cores 21 and 24 of the coaxial separation type transformer 20 shown in FIG. 7 are manufactured as follows. For example, the core 21 is formed by winding an electric wire 22b around a ring-shaped bobbin 22a that is long in the axial direction at a predetermined interval to form a coil 22 and disposing the coil 22 in a mold so that the same soft magnetic resin 3 as the soft magnetic resin 3 is melted. It is manufactured by molding with resin 23.

On the other hand, the core 24 is provided with a wire 25b wound in a ring shape in advance at a predetermined interval inside a ring-shaped bobbin 25a that is long in the axial direction to form a coil 25.
In the same manner as described above, the coil 25 is manufactured by molding with a soft magnetic resin 26 having the same composition as the soft magnetic resin 23. At this time, the bobbins 22a and 25a
The core may be formed into a ring shape using a second synthetic resin having the same composition as that described above. However, when the injection pressure of the soft magnetic resin at the time of forming the core is high, the ring-shaped soft resin is prevented from being deformed. A magnetic ferrite sintered body may be used.

The bobbins 15a to 17a and the bobbin 22
When a soft magnetic ferrite sintered body is used for a and 25a, it is preferable to use one having a relative magnetic permeability equal to or higher than the soft magnetic resin which is injected into the cavity and forms the core. In the above-described embodiment, the description has been given of the cylindrical separation type transformer. However, even if at least one of the core and the coil has a non-circular cross-sectional shape such as a rectangle or an ellipse and a cylindrical separation type transformer structure. Applicable.

Here, a core obtained by molding a coil formed into a predetermined shape with a molten high-pressure soft magnetic resin without using a bobbin, for example, as shown in FIG. When manufacturing the core 30 molded with the same soft magnetic resin 32 as described above, the following is performed. First, an electric wire is wound around a core 33 having a predetermined diameter (see FIG. 9) to form a coil 31, and an adhesive or the like is applied as needed to maintain the shape.

Next, as shown in FIG. 9, the coil 31 and the core 33 together with the molds 34, 3 of an injection molding machine (not shown).
5 and the molten soft magnetic resin 32 is injected from the runner 34a of the mold 34 into the annular cavity C1 at a high pressure. Thus, the soft magnetic resin 32 fills the entire cavity C1 and the soft magnetic resin 32 is molded on the outer peripheral side of the coil 31.

After the soft magnetic resin 32 has cooled to a predetermined temperature, the molds 34 and 35 are opened to mold the core intermediate 30 shown in FIG.
Take out a. Next, as shown in FIG. 11, the core intermediate 30a is placed in the molds 36 and 37 of an injection molding machine (not shown), and the soft magnetic resin 32 melted from the runner 36a of the mold 36 is placed in the annular cavity C2. Inject at high pressure. As a result, the soft magnetic resin 32 fills the entire cavity C2, and the soft magnetic resin 32 is molded on the outer and inner peripheral sides of the coil 31 as shown in FIG.
Is manufactured.

After the soft magnetic resin 32 has cooled to a predetermined temperature, the molds 36 and 37 are opened and the core 30 is taken out. Therefore, since the core 30 is molded with the soft magnetic resin 32 that melts the inner and outer circumferences of the coil 31, the coil 31 can be provided inside the core 30 very easily.
There is no gap between the coil and the coil 31. Therefore, core 3
The separation type transformer using 0 can improve the transmission efficiency of electric power and the like.

On the other hand, in the separated type transformer core, it is generally practiced to draw out the end of the coil to the outside of the core and connect it to an external electric circuit or the like. In this case, conventionally, a lead-out hole or a slit of the coil is formed in the core in advance, and the end of the coil is drawn out to the outside such as the back side of the core or the outside in the radial direction by using these lead-out holes. Was. For this reason, since the coil electric wire is thin, there is a problem that when the coil is pulled out of the core, the coil is easily broken, handling requires care, and workability is deteriorated. In order to solve this, if the lead hole and the slit are formed large, the gap of the core which becomes the magnetic circuit becomes large by that amount, so that the effective relative magnetic permeability, and therefore,
There is a problem that the transformer characteristics are deteriorated.

Therefore, a separate type transformer core in which the coil can be easily pulled out and the deterioration of the transformer characteristics is suppressed is described below. First, in the case of a core that pulls out a coil to the back side of the opposed core, FIG.
The bobbin 40 shown in FIG. The bobbin 40 has a relative magnetic permeability equal to or higher than that of the soft magnetic resin 3 forming the core. For example, the bobbin 40 is formed by molding the soft magnetic resin into a ring shape or by sintering a soft magnetic ferrite molded into a ring shape. As shown, the terminal block 40a
Are provided in the circumferential direction. Two terminals 40b made of a conductive metal such as copper are embedded in the terminal block 40a.

Here, the terminal 40b is connected to the bobbin 40
For example, the bobbin 40 may be fixed by screws after molding, or a terminal block with terminals may be separately fixed to the bobbin 40 by screws or an adhesive.
The terminal block is similar to a terminal block 40c shown in FIG.
The terminal may be provided so as to project radially outward with respect to the bobbin 40, and two terminals 40b are embedded in the terminal block 40c.

Then, as shown in FIG. 12 (b), the electric wire 41a is wound around the bobbin 40 by the required number of turns corresponding to the transformer application to form the coil 41, and each terminal of the electric wire 41a is connected to each terminal 40b. Here, the connection between the terminal of the electric wire 41a and the terminal 40b may be appropriately selected according to the connection strength, such as welding such as soldering, spot welding, resistance welding or ultrasonic welding, or screw fixing. Further, the coil 41 may be bonded with an adhesive or the like in order to maintain the shape of the electric wire 41a.

Next, as shown in FIG. 14, the coil 41 is placed in the molds 42, 43 of an injection molding machine (not shown), and the soft magnetic resin melted from the runner 42a of the mold 42 is annularly formed. Into the cavity C at a high pressure. Thus, the soft magnetic resin fills the entire cavity C, and the core is manufactured. At this time, the terminal block 4 of the coil 41c
Oa enters the mold 42 and is not in the cavity C. For this reason, the coil 41 is only molded on the outer peripheral side of the bobbin 40 together with the electric wire 41a by the soft magnetic resin, and the terminal block 40a is exposed without being molded by the soft magnetic resin.

After the soft magnetic resin has cooled to a predetermined temperature, the molds 42 and 43 are opened to take out the core.
Therefore, in the manufactured core, the terminal of the electric wire 41a is connected to the terminal 40b of the terminal block 40a exposed to the outside and is drawn out to the outside, and the terminal 40b is easily connected to an external electric circuit or the like. Can be connected to

On the other hand, in the case of a core in which the coil is drawn radially outward of the opposed core, the electric wire 46a is wound around a bobbin 45 to form the coil 46 and the electric wire 46a is formed as shown in FIG. Each terminal is pulled outward by a predetermined length calculated from the outer diameter of the core for manufacturing the terminal, and connected to each terminal 47 a of the terminal block 47. Next, the coil 46
In the same manner as the coil 41, an injection molding machine (not shown)
The molten soft magnetic resin placed in the mold is injected at a high pressure to produce a core in which the coil 46 is molded with the soft magnetic resin P.

Accordingly, in the manufactured core, similarly to the above, the terminal of the electric wire 46a is connected to the terminal 47a of the terminal block 47 located radially outward and is drawn out to the outside. It can be easily connected to an external electric circuit or the like by using the 47a. By the way, the core of the present invention manufactured by molding a bobbin with a soft magnetic resin is incorporated in a steering device of an automobile and used as a separate type transformer of a power transmission device for detonating an airbag device attached to the steering. Therefore, it is necessary to increase the adhesion strength between the bobbin and the soft magnetic resin so that the bobbin does not peel off or fall off from the core due to vibration or impact.

As a core meeting such a demand, for example, a coil 48 shown in FIG. 16 is used. Coil 48
Is a bobbin 4 having a flange 49a as shown in FIG.
9, the electric wire 48a is wound by the required number of turns corresponding to the transformer application, and the electric wire 48a may be adhered with an adhesive or the like to maintain the shape.

The bobbin 49 is made of a second synthetic resin having the same composition as the soft magnetic resin 3 and is formed into a ring shape or the sintered soft magnetic ferrite is formed into a ring shape. . The bobbin 49 is made of a material having a relative permeability equal to or higher than that of the soft magnetic resin to be molded so as not to lower the magnetic performance of the separation type transformer.

Since the coil 48 has the flange 49a formed on the bobbin 49 as described above, the core using the coil 48 increases the contact area between the bobbin 49 and the soft magnetic resin, thereby increasing the adhesion strength. . Further, if the terminal of the electric wire 48a wound around the flange 49a is supported, the working efficiency is improved, and the precision at the time of molding can be improved. on the other hand,
For example, even if the bobbin 50 shown in FIG. 17 or the bobbin 51 shown in FIG. 18 is used, the contact area with the soft magnetic resin increases,
The adhesion strength with the soft magnetic resin can be increased.

That is, the bobbin 50 is formed in a ring shape, and a contact hole 50a having an appropriate depth is formed in a spot on the outer surface on which the soft magnetic resin is molded. On the other hand, the bobbin 51 is formed in a ring shape, and an oblique groove-shaped contact groove 51a is formed diagonally on the outer surface on which the soft magnetic resin is molded. At this time, the bobbin 51 forms the contact groove 51a obliquely, forms a contact groove in a direction parallel or perpendicular to the central axis, or forms a ridge in place of the groove,
It is also possible to adopt an uneven structure in which a close contact hole such as the bobbin 50 and a close contact groove or protrusion such as the bobbin 51, and further, a protrusion are appropriately combined at random.

Further, in order to increase the adhesion strength between the core and the coil, a coil 58 shown in FIG. 23 or a coil 59 shown in FIG. 24 may be used. That is, as shown in FIG. 23, the coil 58 is connected to a ring-shaped bobbin 58a molded in the shape of an inverted truncated cone using a second synthetic resin having the same composition as the soft magnetic resin 3 or the soft magnetic ferrite sintered body. 5
8b. On the other hand, the coil 59
As shown in FIG. 4, a ring-shaped bobbin 59a molded into a drum shape in which the middle of the outer wall bulges outward by a second synthetic resin having the same composition as the soft magnetic resin 3 or the sintered soft magnetic ferrite. The wire 59b is wound.

On the other hand, when a core manufactured by molding a soft magnetic resin as a bobbin is used as a core for a rotary transformer, the core may be displaced due to eccentricity between the cores arranged opposite to each other, or may be caused by the inclination of the facing surface. Fluctuation of the distance between the cores, that is, the gap, due to the rotation of the rotor greatly affects the performance of the transformer. For this reason, in the conventional rotary transformer, the manufactured core is housed in a separately prepared outer case, or the manufactured core is mounted on a mounting base or the like so as to be aligned. In particular, in the case of a core using a bobbin made of a ferrite sintered body, the core is easily broken or chipped by impact or vibration, so that an outer case and an impact absorbing means are required.

Therefore, the conventional core has a problem that high manufacturing accuracy is required and manufacturing cost is high. Therefore, as a core avoiding such a problem, for example, a core 52 having a structure shown in FIGS. 19A and 19B is used.
That is, the core 52 is formed into a ring shape by molding a coil 53 formed into a predetermined shape with a molten soft magnetic resin 54 containing a soft magnetic material, and a mounting portion 5 is formed on the lower outer periphery.
2a are provided at three locations protruding radially outward. The mounting portion 52a is integrally formed with the screw hole 52b at the center when the coil 53 is molded with the soft magnetic resin 54 using a molding die (not shown).

Therefore, in the manufactured core 52,
The position of the coil 53 and the screw hole 52b of the mounting portion 52a is
Since the adjustment can be performed with high accuracy by correcting the molding die, it is determined by an error in the molding accuracy of the core 52. Also, like a core 55 shown in FIGS. 20 (a) and 20 (b), a coil 56 formed into a predetermined shape is molded with a molten soft magnetic resin 57 containing a soft magnetic material to form a ring shape. The mounting portion 55a may be provided at three locations (two locations are not shown) protruding radially outward on the outer periphery. The mounting portion 55a has two screw holes 55b, and is integrally formed in the vertical direction in parallel with the axial direction of the core 55 when the coil 56 is molded with the soft magnetic resin 57 by a molding die (not shown).

Further, the core 6 shown in FIGS.
A coil formed into a predetermined shape such as 0 (not shown)
Is molded with a molten soft magnetic resin 62 containing a soft magnetic material to form a ring shape, and at four locations (2
(A place is not shown), the attachment part 60a may be provided. The attachment portion 60a is provided with a tap hole 60b. Further, like a core 65 shown in FIG. 22, a coil (not shown) formed in a predetermined shape is molded with a molten soft magnetic resin 66 containing a soft magnetic material to form a ring shape, Forming a screw-shaped projection 65a;
May be engaged with a female screw-shaped groove formed on the object to be attached.

At this time, in each of the above-mentioned cores, the mounting portion and the mounting base are appropriately changed in shape, forming position and number in accordance with the mounting strength, the shape and structure of the mounting object, and the like. On the other hand, when higher mounting accuracy is required for the core, a positioning pin for positioning the molding dies with high precision during core molding may be used. It goes without saying that the electric wire used in the core of each embodiment may be either a winding having a circular cross section or a flat winding having a square cross section.

[0046]

According to the first aspect of the present invention, the coil can be easily provided on the core, there is no gap between the core and the coil, and the efficiency of transmission of power and the like can be improved. A method for manufacturing a core can be provided.
According to the invention of claim 2, deformation of the coil when molding the coil can be suppressed by the bobbin.

According to the third and fourth aspects of the present invention, it is possible to suppress a decrease in the transmission efficiency of the core to be formed. According to the fifth aspect of the present invention, the coil can be easily pulled out to the outside, and a decrease in transformer characteristics can be suppressed. According to the sixth aspect of the present invention, it is possible to manufacture a facing separated transformer core having a plurality of coils.

According to the seventh aspect of the invention, it is possible to manufacture a coaxial opposed-separation type transformer having a plurality of coils. According to the invention of claim 8, it is possible to manufacture a core in which deformation of the coil is suppressed without using a bobbin. According to the ninth aspect of the present invention, the contact area between the first synthetic resin and the bobbin is increased, so that the adhesion strength between the first synthetic resin and the bobbin can be increased. When used for a separation type transformer, the reliability of the separation type transformer is improved.

According to the tenth aspect of the present invention, it is possible to easily attach and use without using an outer case or a shock absorbing means.

[Brief description of the drawings]

FIG. 1 is a sectional view of a separated transformer core manufactured by the method of the present invention.

FIG. 2 is a cross-sectional view showing a state in which a coil is placed in a molding die and molded with a molten first synthetic resin containing a soft magnetic material to produce a core.

FIG. 3 is a cross-sectional view of another separated type transformer core manufactured by the method of the present invention.

FIG. 4 is a cross-sectional view illustrating a method of manufacturing the core of FIG. 3 in a state where an electric wire is wound around a bobbin to form a coil.

FIG. 5 is a cross-sectional view showing a state in which the coil of FIG. 4 is arranged in a mold, and is molded with a molten first synthetic resin containing a soft magnetic material to produce a core.

FIG. 6 is a partial cross-sectional view illustrating a method of manufacturing a core for a facing-separated type transformer having a plurality of coils.

FIG. 7 is a sectional perspective view showing a part of a coaxial separation type transformer core having a plurality of coils.

FIG. 8 is a sectional view of still another separated transformer core manufactured by the method of the present invention.

FIG. 9 illustrates a method of manufacturing the core shown in FIG. 8,
It is sectional drawing which shows the state which arrange | positions the core which wound the coil in the shaping | molding die, and molds 1st synthetic resin on the outer peripheral side of a coil.

FIG. 10 is a cross-sectional view of a core intermediate body in which a first synthetic resin is molded on an outer peripheral side of a coil.

FIG. 11 is a cross-sectional view showing a state in which the core intermediate of FIG. 10 is arranged in still another mold, and a first synthetic resin is molded on the inner peripheral side of the coil.

FIG. 12A is a perspective view of a bobbin used for manufacturing another separated type transformer core manufactured by the method of the present invention, and FIG. 12B is a perspective view of a coil having an electric wire wound around the bobbin.

FIG. 13 is a cross-sectional view showing the shape of another coil used for manufacturing a separate transformer core.

FIG. 14 is a cross-sectional view showing a state in which the coil shown in FIG. 12 is molded with a molten first synthetic resin containing a soft magnetic material to manufacture a separated transformer core.

FIG. 15 is a cross-sectional view showing the shape of still another coil used for manufacturing a separate transformer core.

FIG. 16 is a perspective view of a coil used for manufacturing another separated type transformer core manufactured by the method of the present invention.

FIG. 17 is a perspective view of a bobbin used for manufacturing another separated type transformer core manufactured by the method of the present invention.

FIG. 18 is a perspective view of another bobbin used for manufacturing another separated transformer core manufactured by the method of the present invention.

FIG. 19 is a front view (a) and a plan view (b) showing another separated type transformer core manufactured by the method of the present invention.

FIGS. 20A and 20B are a front view and a plan view, respectively, showing a half of still another separated type transformer core manufactured by the method of the present invention.

FIG. 21 is a front view (a) showing a half of another separated type transformer core manufactured by the method of the present invention, and a plan view (b) thereof.

FIG. 22 is a front view of still another separated transformer core manufactured by the method of the present invention.

FIG. 23 is a sectional view of a coil used for manufacturing another separated type transformer core manufactured by the method of the present invention.

FIG. 24 is a sectional view of another coil used for manufacturing another separated type transformer core manufactured by the method of the present invention.

[Explanation of symbols]

 Reference Signs List 1 core 2 coil 3 soft magnetic resin 10 core 11 coil 11a bobbin 11b electric wire 12 soft magnetic resin 15 to 17 coil 15a to 17a bobbin 15b to 17b electric wire 20 coaxial separation type transformer 21, 24 core 22, 25 coil 22a, 25a bobbin 22b , 25b electric wire 23, 26 soft magnetic resin 30 core 31 coil 32 soft magnetic resin 40 bobbin 41 coil 41a electric wire 45 bobbin 46 coil 46a electric wire 48 coil 48a electric wire 49 bobbin 49a flange portion 50 bobbin 50a adhesive hole 51 bobbin 51a adhesive groove 52 55, 60 cores 53, 56, coils 54, 57, 62 soft magnetic resin 58, 59 coil 65 core 66 soft magnetic resin

Claims (10)

[Claims] 1. A coil formed into a predetermined shape is molded with a molten first synthetic resin containing a soft magnetic material,
A method for producing a separated transformer core, which is formed into a desired shape. 2. The separation type transformer according to claim 1, wherein an electric wire is wound around a bobbin having soft magnetism to form a coil having a predetermined shape, and then molded with the molten first synthetic resin into a desired shape. Core manufacturing method. 3. The second bobbin containing a soft magnetic material.
3. The method for producing a separated transformer core according to claim 2, comprising a synthetic resin. 4. The method according to claim 2, wherein said bobbin is made of soft magnetic sintered ferrite. 5. The method for manufacturing a separate transformer core according to claim 1, wherein a bobbin provided at an end of the wire extending and wound integrally or with a connection portion connected to the external wire is used. 6. A coil having a predetermined shape is formed by winding an electric wire around each of a plurality of bobbins having different radii, and is molded into a desired shape by molding with the molten first synthetic resin.
A method for manufacturing a separated transformer core according to any one of claims 2 to 4. 7. A plurality of coils are wound at predetermined intervals in the axial direction of the bobbin to form a predetermined shape, and then molded with the molten first synthetic resin to form a desired shape.
A method for manufacturing a separated transformer core according to any one of claims 2 to 4. 8. After the molten first synthetic resin containing a soft magnetic material is molded on one of the outer peripheral side and the inner peripheral side of the coil formed into a predetermined shape, the inner peripheral side or the outer peripheral side is further molded. 2. The method according to claim 1, wherein the first synthetic resin containing a soft magnetic material is molded on the other side. 9. A coil having a predetermined shape is formed by winding an electric wire around a bobbin having a soft magnetism and having a concavo-convex structure for increasing a contact area with the first synthetic resin. 2. The method for producing a separated transformer core according to claim 1, wherein the molded transformer is molded into a desired shape by molding with a synthetic resin. 10. The method for manufacturing a separate transformer core according to claim 1, wherein the mounting portion is integrally formed outside at the time of molding.