JP2001167930A - Coil for inductor and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to manufacture a coil having even a large cross- sectional area that can make a large current flow and to provide an inexpensive coil for an inductor. SOLUTION: A U-shaped conductive plate 10 and a C-shaped insulating plate 12 are laminated one after the other in a given direction so as to form a spiral, and they are heated while being pressed and are bonded with solder 17. In this coil for the inductor, it is not necessary to roll a conductive wire like a toroidal coil. Also, the coil can be manufactured only by bonding a designated- shape conductive plate 1 and laminating it. In addition, it is possible to ensure the insulation between the turns of the coil by laminating the conductive plate and the insulating plate one after the other, and inductance can be surely obtained as originally designed when the inductor is constructed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a coil for an inductor and a method for manufacturing the same.

[0002]

2. Description of the Related Art A coil for an inductor is a noise filter for a power converter provided for filtering a switching noise generated by a switching operation of a semiconductor switching element constituting a power converter such as a choke coil of an electric device or an inverter. It is used for inductors for applications.

[0003] Among noises generated by the switching operation of a semiconductor switch element constituting a power converter such as an inverter, a noise filter for power conversion is provided with a power converter noise filter so as to suppress an adverse effect on external devices by a component of 100 kHz or more. It is required to be installed in

A conventional noise filter for power conversion of this type includes an inductor formed of a coil having a toroidal shape in which a wire is wound around a ring core and a capacitor formed of a dielectric such as a film or a ceramic chip. The filter is constituted by connecting the filters in a shape, and the filter filters out switching noise generated by the switching operation of the semiconductor switch element.

A toroidal coil serving as an inductor is generally formed by winding a covered conductive wire 8 around a ring core 7 made of a magnetic material such as ferrite, an amorphous alloy, or a crystalline alloy, as shown in FIG. .

[0006]

In a large-capacity inverter or the like, it is necessary to use a conductor having a large sectional area for a coil used for an inductor. With a conventional toroidal inductor, it was difficult to wind a thick conductor wire having a large cross-sectional area. Also, to wind a thick wire,
There is a problem that the entire shape needs to be large and a large mounting space is required.

It is an object of the present invention to provide a smaller and less costly inductor coil which solves the above problems.

[0008]

According to a first aspect of the present invention, a plurality of conductive plates are provided with a conductive portion formed by spirally bonding and laminating a part of the plurality of conductive plates with solder or a conductive adhesive. I do.

According to a second aspect of the present invention, in the first aspect, the conductive portion is formed by alternately stacking the conductive plates and the insulating plates.

A third aspect of the present invention is characterized in that, in the first or second aspect, the conductive plate is C-shaped, U-shaped or L-shaped.

According to a fourth aspect of the present invention, in the second aspect, the insulating plate is C-shaped or L-shaped.

According to a fifth aspect of the present invention, a plurality of conductive plates partially covered with solder or a conductive adhesive are laminated in a spiral shape, and the solder or the conductive adhesive is heated or pressed to form a conductive film. The method is characterized in that a part is created.

According to a sixth aspect of the present invention, in the fifth aspect, the conductive portion is formed by alternately stacking the conductive plate and the insulating plate.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an example of a conductive plate according to a first embodiment of the present invention, and FIG. 2 shows a conceptual diagram of an inductor using a coil made from the conductive plate.

The conductive plate 1 shown in FIG. 1 has a C-shape (a shape having a cutout in a part of a ring shape), and a conductive portion forming an inductor coil spirals a plurality of conductive plates 1. It is formed by bonding and laminating a part with solder or a conductive adhesive so as to form a shape. FIG. 2 shows an example of an inductor using the above coil, which has a coil for two phases,
Each of the coils 2A, 2B is formed by alternately laminating the conductive plate 1 and the insulating plate 4, and is configured by putting each of the two coils 2A, 2B into each of two E-shaped cores 6. It is. Such an inductor coil does not need to be wound with a conductive wire like a toroidal coil, and can be manufactured simply by bonding and laminating a conductive plate 1 having a specified shape. For this reason, processing costs can be reduced,
It can be manufactured at low cost. In addition, since there is no large space at the center and conductors can be densely arranged,
This results in a smaller inductor. Furthermore, since the shape is simple, mounting is easy, and the mounting space can be reduced.

The bonding portion 5 of the coil is made of solder or a conductive adhesive, and is manufactured by sequentially laminating the conductive plates 1 partially covered with the solder or the conductive adhesive and heating or pressing. Therefore, a coil having many turns can be manufactured at a time, and the processing cost can be reduced.

Further, the coil is formed by alternately laminating the conductive plate 1 and the insulating plate 4, thereby ensuring insulation between turns. When an inductor is formed, the inductance as designed is ensured. Obtainable.

FIG. 4 shows another conductive plate. 9 is a C-shaped conductive plate, 10 is a U-shaped conductive plate, and 11 is an L-shaped conductive plate.
According to such a conductive plate, the thickness of the entire coil can be suppressed and the size of the coil can be reduced by reducing the number of laminated portions or changing the number of laminated portions.
In the case where individual conductive plates are manufactured from a large plate by punching or electric discharge machining, the conductive plates can be effectively manufactured with little margin. FIG. 5 shows the insulating plate. Reference numeral 12 denotes a C-shaped insulating plate, and reference numeral 13 denotes an L-shaped insulating plate. By sandwiching these insulating plates between the conductive plates of the respective layers to produce a coil, the number of interlayer insulating portions can be reduced, and the layers can be effectively laminated. Therefore, the thickness of the entire coil can be suppressed, and the coil can be reduced in size. In the case where individual insulating plates are produced from a large plate by punching or electric discharge machining, the insulating plates can be effectively produced with little margin and can be produced at low cost.

According to the present invention, a coil is formed by laminating conductive plates, and then an inductor is manufactured by inserting the coil into a core. Therefore, unlike a toroidal coil, a conductor wire is not wound around a ring core. It is possible to easily manufacture an inductor. Since a large space like a toroidal coil is not required, the size can be reduced, and the mounting space can be made smaller because it is not a circular shape but a rectangular parallelepiped like a toroidal coil.

FIG. 6 shows an example of a circuit in which an inductor is used as a noise filter for a power converter using an interphase capacitor. The filter circuit 14 is built in the inverter. The dotted line is the filter circuit 14, and the inductor L is installed at a DC intermediate on the output side of the rectifier diode 16. According to the present invention, the inductor L can be manufactured in a small size and at low cost. Since the inductor L can be reduced in size, the overall size can be reduced even if the filter circuit 14 is built in the inverter body. As described above, a noise filter for a power converter provided for filtering switching noise generated due to a switching operation of a semiconductor switch element forming a power converter is combined with an inductor and a capacitor of the present invention to form a filter circuit. By doing so, a small and inexpensive noise filter for a power converter can be provided.

(Example) First Example As shown in FIG. 7, a predetermined shape of a U-shaped conductive plate 10 obtained by punching a copper plate having a thickness of 0.5 mm into a U-shape having an outer shape of 24 mm and a width of 8 mm as shown in FIG. Solder 17 was printed at each location. The upper and lower U-shaped copper plates 10A and 10B have longer sides so that the leads can be easily taken out. Separately, a C-shaped insulating plate 12 was prepared by punching a glass epoxy sheet having a thickness of 0.1 mm into a C-shaped shape having an outer shape of 25 mm and a width of 8.5 mm and having no center and one corner.

Next, as shown in FIG.
0 and C-shaped insulating plates 12 are alternately laminated in a predetermined direction so that the conductive portions are helical, and are heated while being pressurized.
And adhered. Leads were attached to the uppermost stage and the lowermost stage, and the periphery was insulated with a silicone resin to produce a coil 2.

As shown in FIG. 2, a coil 2 for two phases is put in one inductor to constitute a filter circuit. Two coils 2A and 2B whose periphery were insulated were placed in a ferrite E-shaped core 4 to produce an inductor. A good result was obtained as a result of configuring the filter circuit shown in FIG. 6 using this inductor and evaluating the noise terminal voltage. Also, the size of the filter circuit could be reduced to 1/3 of that in the case where a conventional toroidal coil was used (as a specific example, 3 times).
In the 5A 3.7 kW type filter circuit, a filter circuit using a conventional toroidal coil is 170 × 110 × 60.
mm, whereas in the present embodiment, it is 15 mm.
The size became 0 × 75 × 30 mm. ).

Second Embodiment As shown in FIG. 9, a copper plate having a thickness of 0.5 mm and an outer shape having a width of 24 mm and a width of 8 mm are used.
Solder 17 was printed on a predetermined portion of the U-shaped conductive plate 10 punched into a U-shaped mm. One side of each of the U-shaped conductive plates 10A and 10B at the uppermost stage and the lowermost stage is elongated in order to easily take out the leads. Separately, an L-shaped insulating plate 13 was prepared by punching a 0.1 mm-thick glass epoxy sheet into an L-shape with an outer shape of 25 mm and a width of 8.5 mm as shown in FIG. Punching margin of copper plate and glass epoxy plate is reduced,
As a result, it was possible to fabricate the first embodiment at a lower cost. The production of the coil and the production of the inductor were performed in the same manner as in the first embodiment. A coil having the same number of turns as in the first embodiment was manufactured, but the thickness of the coil was increased by a factor of 1.5.

The filter circuit shown in FIG. 6 was constructed using this inductor, and the noise terminal voltage was evaluated. As a result, good results were obtained. Also, the size of the filter circuit could be reduced to one-half that of the case where a conventional toroidal coil was used. (As a specific example, a 35A 3.7 kW type filter circuit using a conventional toroidal coil has a smaller size. ,
In contrast to the size of 170 × 110 × 60 mm, in the present embodiment, the size was 150 × 75 × 50 mm. ).

Third Embodiment As shown in FIG. 10, a solder 17 was printed on a predetermined portion of an L-shaped conductive plate 11 formed by punching a 0.5 mm-thick copper plate into an L-shape having an outer shape of 24 mm and a width of 8 mm. L-shaped conductive plate 11A at the top
Lengthened one side to make it easier to take out the lead.
The lowermost conductive plate 11B is an I-shaped conductive plate which is longer than the other conductive plates in order to facilitate taking out the leads. Separately,
As shown in FIG. 10, an L-shaped insulating plate 13 was prepared by punching a 0.1 mm-thick glass epoxy sheet into an L-shape with an outer shape of 25 mm and a width of 8.5 mm. It was thought that the punching-out margin of the copper plate and the glass epoxy plate was reduced, so that it could be manufactured at a lower cost than the first embodiment. The production of the coil and the production of the inductor were performed in the same manner as in the first embodiment. A coil having the same number of turns as in the first embodiment was manufactured, but the thickness of the coil was increased by a factor of 1.5.

The filter circuit shown in FIG. 6 was constructed using this inductor, and the noise terminal voltage was evaluated. As a result, good results were obtained. Also, the size of the filter circuit could be reduced to one-half that of the case where a conventional toroidal coil was used. (As a specific example, a 35A 3.7 kW type filter circuit using a conventional toroidal coil has a smaller size. ,
In contrast to the size of 170 × 110 × 60 mm, in the present embodiment, the size was 150 × 75 × 50 mm. ).

[0028]

As described above, according to the present invention, even a coil having a large cross-sectional area through which a large current can flow can be manufactured by laminating the conductive plates, so that the gap can be reduced and the device can be manufactured in a small size. Become. In addition, the process can be simple and inexpensive.

[Brief description of the drawings]

FIG. 1 is a diagram illustrating an example of a conductive plate.

FIG. 2 is a conceptual diagram of an inductor.

FIG. 3 is a conceptual diagram of a toroidal coil which is a conventional inductor.

FIG. 4 is a diagram showing an example of another conductive plate.

FIG. 5 is a diagram showing an example of an insulating plate.

FIG. 6 is a circuit diagram of an inverter with a built-in filter.

FIG. 7 is a diagram showing an example of the shape of a U-shaped conductive plate and a C-shaped insulating plate.

FIG. 8 is a view showing a lamination mode of a U-shaped conductive plate and a C-shaped insulating plate.

FIG. 9 is a view showing another example of the shapes of the U-shaped conductive plate and the L-shaped insulating plate.

FIG. 10 is a diagram showing an example of the shape of an L-shaped conductive plate and an L-shaped insulating plate.

[Explanation of symbols]

 10 U-shaped conductive plate 12 C-shaped insulating plate 17 Solder

Continuation of the front page (72) Inventor Kenji Okamoto 1-1, Tanabe-Nitta, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture F-term in Fuji Electric Co., Ltd. (reference) 5E043 AA02 AB04 BA03 5E062 EE01 5E070 AA01 AB01 BA08 CC02 CC04 DA04 DA15

Claims (6)

[Claims] 1. A coil for an inductor, comprising: a conductive part in which a plurality of conductive plates are partly adhered and laminated by soldering or a conductive adhesive so as to form a spiral. 2. The inductor coil according to claim 1, wherein the conductive portion is formed by alternately stacking the conductive plates and the insulating plates. 3. The inductor coil according to claim 1, wherein the conductive plate is C-shaped, U-shaped, or L-shaped. 4. The inductor coil according to claim 2, wherein the insulating plate is C-shaped or L-shaped. 5. A method of forming a conductive part by laminating a plurality of conductive plates on which solder or conductive adhesive is partially applied so as to form a spiral, and heating or pressing the solder or conductive adhesive. A method for manufacturing an inductor coil, comprising: 6. The method for manufacturing an inductor coil according to claim 5, wherein the conductive portion alternately laminates the conductive plate and the insulating plate.