JP2001257124A - Choke coil and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a choke coil, which reduces the number of metal mold jig tools for magnetic cores to reduce the manufacturing cost of the choke coil, can be easily assembled and is superior in mass production, and to provide the manufacturing method of the choke coil. SOLUTION: A choke coil consisting of a soft magnetic material, which is a cylindrical body with the external shape of substantially rectangular parallelepiped form and is formed with sectional form of its cylindrical part into almost a rectangular form, and a conductive plate 2 penetrating the cylindrical part with a portion, which is exposed outside of the soft magnetic material and is bent at almost a right angle, is constituted into a structure that the soft magnetic material is formed by coupling two magnetic cores 1 and 3, which are formed into substantially the same form and have the L-shape section, with each other in opposition to each other, the core on at least one side of the two cores 1 and 3 has a recess in one part of the bonded surface of the core to the other magnetic core and the surface interval which is one part, which is positioned in the interior of the soft magnetic material, of the plate 2 and is at least one side of the surface intervals opposing to each other between the cores 1 and 3, is almost the same as the surface interval of the internal wall of the cylindrical part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a choke coil suitable for use mainly as a power source for electronic equipment and a method for manufacturing the same.

[0002]

2. Description of the Related Art An external view of a conventional choke coil is shown in FIG. The conventional choke coil shown in FIG.
The conductive plate 2 whose both ends are bent in a U-shape is fitted into a substantially central portion of the spacer 5 from the side direction, and a U-shaped magnetic core 6 is combined.

[0003] The position of the conductive plate has been determined by combining a U-shaped magnetic core, which is the final step. The characteristic adjustment of the choke coil has been performed by adjusting the gap by attaching the spacer 5 to the I-type magnetic core 4. However, in the step of attaching the spacer 5, the magnetic core 4 and the spacer 5 are attached.
It takes an assembling time to make adjustments so as not to cause the positional deviation.

[0004]

In a conventional choke coil, there are two types of magnetic cores, a U type and an I type. For this reason, there are only two mold jigs and tools required for manufacturing each magnetic core. Type and therefore the cost of the mold tooling,
In addition, there are two types of manufacturing steps required for the magnetic core. Therefore, the first problem to be solved is to use only one type of mold jig.

The conductive plate 2 is attached to the I-type magnetic core 4.
When the U-shaped magnetic core 6 is fitted, there is a problem that the position of the conductive plate 2 cannot be determined until the U-shaped magnetic core 6 is combined.
Therefore, the second problem to be solved is to easily determine the position of the conductive plate 2.

Further, the method of adjusting the inductance gap at the time of manufacturing a choke coil has been performed by attaching a spacer 5 to the I-type magnetic core 4. However, spacer 5
The problem is that they are easily displaced and work efficiency is poor.
Therefore, a third problem to be solved is to facilitate the operation of assembling the choke coil.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to reduce the number of jigs and tools for the magnetic core, simplify the manufacturing process, reduce the manufacturing cost, and assemble the choke coil with excellent mass productivity. It is to provide a manufacturing method.

[0008]

The choke coil of the present invention has a structure using two L-shaped magnetic cores in order to solve the above-mentioned problems. A conductive plate whose both ends are bent in a U-shape is fitted into one of the L-shaped magnetic cores so that a part of the joining surface of the L-shaped magnetic core is fitted, and another L-shaped magnetic core of the same shape is fitted. Are combined in opposition to the other.

In the method of adjusting the inductance gap, one upper or lower horizontal surface of the L-shaped magnetic core is cut into a concave shape when viewed from the side surface. By using two L-shaped magnetic cores of the same type, only one type of mold jig, which has conventionally required two types of U-type and I-type, is required.
The position of the conductive plate can be determined by abutting the inner vertical surface of the L-shaped magnetic core with the side surface of the conductive plate.

Further, the adjustment of the inductance gap can omit the spacers, the number of assembling steps is reduced, and the work efficiency is improved as compared with the conventional case of attaching the spacers to the I-type magnetic core.

That is, the present invention provides a soft magnetic material having a substantially rectangular parallelepiped outer shape and a substantially rectangular cross-sectional shape of the cylindrical portion;
In a choke coil formed of a conductive plate penetrating through the cylindrical portion whose portion exposed to the outside of the soft magnetic material is bent at a substantially right angle, the soft magnetic material has substantially the same shape and has two L-shaped cross sections. The cores are joined to face each other.
At least one of the magnetic cores has a recess in a part of a joint surface with the other magnetic core, and at least one of a distance between surfaces facing each other, which is a part of the conductive plate located inside the magnetic core. And a choke coil having substantially the same distance between the surfaces of the inner wall of the cylindrical portion.

[0012] The present invention also provides a soft magnetic material having a substantially rectangular parallelepiped outer shape and a substantially rectangular cross section.
In a method for manufacturing a choke coil comprising a conductive plate penetrating the cylindrical portion whose portion exposed to the outside of the soft magnetic material is bent at a substantially right angle, the choke coil having substantially the same shape and having an L-shaped cross section
At least one of the magnetic cores is provided with a recess in a part of the joint surface with the other magnetic core, and the conductive plate whose both ends are bent in a U-shape is fitted into one of the magnetic cores. A method for manufacturing a choke coil in which positioning is performed by abutting an inner vertical surface of a core with the conductive plate, and further combined with the other magnetic core so as to face each other.

Further, the present invention is the method of manufacturing a choke coil, wherein a part of a concave portion of a joining surface of the L-shaped magnetic core is formed by polishing and / or grinding.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A choke coil according to an embodiment of the present invention and a method for manufacturing the same will be described below.

FIG. 1 is an explanatory view of a magnetic core having a concave depression used in a choke coil according to an embodiment of the present invention. FIG. 1A is a plan view of a magnetic core, and FIG.
Is a front view, and FIG. 1 (c) is a side view. In FIG. 1, the magnetic core 1 has an L-shape, and has a shape in which a concave recess 1a is provided in a partial section of one core cross section.

FIG. 2 is an external perspective view of a choke coil according to an embodiment of the present invention. FIG. 3 is an explanatory view of a method for manufacturing the choke coil.

The method of manufacturing the choke coil shown in FIG. 3 will be described below. That is, the L-shaped magnetic core 1
Of the conductive plate 2 whose both ends are bent in a U-shape so as to be aligned with the inner vertical surface of the. Here, the width of the conductive plate is substantially equal to a dimension obtained by subtracting the thickness of the magnetic core from the width of the plane portion inside the L-shaped magnetic core, and the dimension inside the U-shape is It is set to be more positive than the thickness.

The position of the conductive plate 2 can be determined from the above dimensional relationship. That is, the portion of the L-shaped magnetic core 1 where the conductive plate is not present on the inner horizontal plane is present only in the region of the lower horizontal surface of the L-shaped magnetic core 3 without the other concave depression. I have. A choke coil is manufactured by combining an L-shaped magnetic core 3 having no concave depression in the region with an L-shaped magnetic core 1 having a concave depression 1a.

One of the L-shaped magnetic cores (FIG. 3)
In the magnetic core 1), the upper horizontal surface is cut into a concave shape to form a concave depression, and the inductance of the choke coil is adjusted by an air gap formed by the concave depression. Furthermore, even if a similar concave depression is provided in both of the L-shaped magnetic cores,
Similarly, the inductance of the choke coil can be adjusted.

Thus, in the conventional choke coil,
When adjusting the inductance with the spacer,
In the step of attaching the spacer, the work efficiency was reduced due to the displacement of the spacer. However, the method for adjusting the inductance gap by the method for manufacturing a choke coil of the present invention reduces the assembly process,
Improvement of the work efficiency of the assembly can be realized.

Therefore, according to the choke coil and the method of manufacturing the same of the present invention, the mold jig for the magnetic core becomes one kind, and the number of steps for manufacturing the magnetic core is reduced. Further, the position of the conductive plate can be determined with good reproducibility, and a choke coil that can be easily assembled can be realized.

[0022]

As described above, according to the present invention, it is possible to provide a choke coil which is reduced in manufacturing cost by reducing the number of mold jigs for a magnetic core, is easy to assemble, and is excellent in mass productivity, and a method of manufacturing the same. Can be.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a magnetic core used in a choke coil of the present invention. 1A is a plan view of the magnetic core, FIG. 1B is a front view, and FIG. 1C is a side view.

FIG. 2 is an external perspective view of a choke coil according to the embodiment of the present invention.

FIG. 3 is an explanatory view of a method for manufacturing a choke coil according to an embodiment of the present invention.

FIG. 4 is an external view of a conventional choke coil.

FIG. 5 is an explanatory diagram of a conventional method for manufacturing a choke coil.

[Explanation of symbols]

 1, 3 (L-shaped) magnetic core 1a Concave depression 2 Conductive plate (both ends bent in U-shape) 4 I-shaped magnetic core 5 Spacer 6 U-shaped magnetic core

Claims (3)

[Claims] 1. A soft magnetic body having a substantially rectangular parallelepiped outer shape and a substantially rectangular cross-sectional shape, and a cylindrical part having a portion exposed to the outside of the soft magnetic body bent at a substantially right angle. In a choke coil made of a penetrating conductive plate, the soft magnetic body is formed by opposing and coupling two magnetic cores having substantially the same shape and an L-shaped cross section, and at least one of the two magnetic cores Has a recess in a part of a joining surface with the other magnetic core, and at least one of a distance between surfaces facing each other, which is a part of the conductive plate located inside, is a surface of the cylindrical portion inner wall. A choke coil characterized by being substantially the same as the distance. 2. A soft magnetic body having a substantially rectangular parallelepiped outer shape and a substantially rectangular cross-sectional shape, and a portion of the soft magnetic body exposed to the outside is bent at a substantially right angle. In a method for manufacturing a choke coil comprising a penetrating conductive plate,
At least one of the two magnetic cores having substantially the same shape and having an L-shaped cross section is provided with a recess in a part of the joint surface with the other magnetic core, and the conductive plate has both ends bent in a U-shape. The choke coil is characterized in that it is fitted into one of the magnetic cores, then positioned by abutting the inner vertical surface of the magnetic core with the conductive plate, and further combined with the other magnetic core so as to face each other. Production method. 3. The method for manufacturing a choke coil according to claim 2, wherein a part of the recess of the joining surface of the L-shaped magnetic core is formed by polishing and / or grinding.