JP2001284130A - Inductance device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inductance device which can be improved in conductor space factor and reduced in current loss. SOLUTION: Primary conductive plates 1, 1A, and 1B are connected together to constitute a winding structure, in a state in which they are stacked up. Likewise, secondary conductive plates 2 and 2A are superposed on the primary side to form a winding structure. The conductive plates 1, 1A, 1B, 2, and 2A, each formed as nearly a flat plate are used for a primary and a secondary side respectively, by which the inductance device of this constitution can be improved in conductor space factor. The conductive plates 1, 1A, 1B, 2, and 2A, serving as a winding structure, are regulated in thickness corresponding to an operating current, by which the inductance device can be reduced in current loss.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inductance element having a winding structure such as a coil or transformer having an air core or a magnetic core.

[0002]

For example, an inductance element such as a coil and a transformer used in a switching power supply device is generally formed by winding a conductive wire having a circular cross section on a bobbin made of resin or paper. A core as a magnetic member is inserted into the center of the conductor wound around the bobbin as necessary. Therefore, in the conventional manufacturing process of the inductance element, at least the work of winding the conductor is indispensable, and in the manufacturing process, the conductor must be wound uniformly while rotating the bobbin, thereby reducing the number of steps. And it is difficult to achieve automated production.

[0003] In the transformer having the above configuration,
Since a wire having a circular cross section is used as the conductor, the conductor occupancy in the core is small, and furthermore, since a bobbin is required, the conductor occupancy is reduced by the amount of the bobbin. It becomes 30 to 40%.

[0004] On the other hand, as a device that can be relatively thinned,
There is a planar transformer, and in this planar transformer, a winding portion is formed by a copper foil on a base material constituting a multilayer substrate. However, it is difficult to use a copper foil having a thickness of 0.1 mm or more. It is also difficult to reduce the thickness of the conductor to 0.1 mm or less, so that the conductor occupancy is 20 to 30%.

Further, in the case of using the above-mentioned wire, a separate terminal fitting or the like is required for external connection, and a step of electrically connecting the wire to the terminal fitting is required, so that it is difficult to reduce the number of manufacturing steps. Yes, similarly, it is necessary to separately attach terminal fittings for external connection in the planar transformer.

Accordingly, the present invention solves the above problems,
It is an object of the present invention to provide an inductance element that can improve the conductor occupancy and reduce the current loss, and further provide an inductance element that has a simple connection structure with the outside.

[0007]

According to a first aspect of the present invention, there is provided a primary element in which an opening is formed in a part of a plate-shaped annular body to provide an end, and a connecting part is provided on the end side. Side and secondary side conductive plates are formed, at least one of these primary side and secondary side conductive plates is used in plurality, and the primary side and secondary side conductive plates are superposed in an insulated state. The conductive plate on the side where a plurality of conductive plates are used has one connecting portion of the upper conductive plate connected to the other connecting portion of the lower conductive plate.

According to the above configuration, since the primary and secondary sides use conductive plates, the conductor occupancy can be improved.
Further, the current loss can be reduced by adjusting the thickness of the conductive plate serving as a winding to the current to be used.

According to a second aspect of the present invention, in the conductive plate on the plurality of sides, the other connection part at the top and the one connection part at the bottom are used as external terminals.

According to the above configuration, by connecting the connecting portion directly to the substrate or the like as an external terminal, heat on the conductive plate side can be efficiently radiated to the substrate side.

According to a third aspect of the present invention, the connecting portion is formed to be bent on one side of the upper and lower sides.

According to the above configuration, the connecting portion can be simply formed by bending the plate portion.

According to a fourth aspect of the present invention, a core is provided on the superposed primary and secondary conductive plates.

According to the above configuration, a transformer having the core, the primary side and the secondary side conductive plates can be obtained.

According to a fifth aspect of the present invention, the conductive plate has a substantially quadrangular shape, and the primary and secondary conductive plates are arranged on different sides in a superposed state. .

According to the above configuration, since the primary side and the secondary side are gathered at different positions, the connection work of the connecting portions on each side becomes easy.

According to a sixth aspect of the present invention, the conductive plate has a substantially rectangular shape, and the primary and secondary conductive plates are arranged such that the connecting portions are disposed on opposite short sides in an overlapping state. is there.

According to the above configuration, the primary side and the secondary side are gathered at different positions, respectively, so that the connection work of the connecting portions on each side is easy, and there is no protrusion on one long side. It can be manufactured compactly.

According to a seventh aspect of the present invention, an insulating sheet is disposed between the superposed conductive plates.

According to the above configuration, the insulating structure can be simplified and the manufacturing can be easily performed.

The invention according to claim 8 is the one wherein a plurality of one of the primary side and the secondary side conductive plates are overlapped, and the other conductive plate is overlapped above and below one of the stacked conductive plates. is there.

According to the above configuration, the assembly can be performed by inserting a plurality of superposed conductive plates between the other conductive plates, thereby facilitating the manufacture.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of an inductance element according to the present invention will be described below with reference to the accompanying drawings. Figure 1
FIG. 7 shows an example in which the inductance element of the present invention is applied to a transformer. As shown in FIG. 7, the primary conductive plates 1, 1A and 1B and the secondary conductive plates 2 and 2A are ,
It is formed from a conductive metal plate represented by copper, brass, or the like, and is obtained by subjecting the metal plate to mechanical processing such as punching (pressing) or wire cutting. The conductive plates 1, 1A, 1B, 2, 2A are:
The annular body 3 has a substantially rectangular planar shape. The annular body 3 has a substantially rectangular hollow portion 4 inside, and has openings 5, 5A, 5B, 6, 6A formed in a part of the annular body 3. Thus, the end portions 3T of the annular body 3 are formed. That is, the ends 3T, 3T of the annular body 3 are located on both sides of the openings 5, 5A, 5B, 6, 6A.

As shown in FIG. 4, the conductive plate 1 on the primary side is
One end 3T has an external terminal 11 which is one connection part.
Is formed, and the other connecting portion 11A is formed at the other end 3T. One connecting portion 12 is formed at one end 3T of the conductive plate 1A, and the other connecting portion is formed at the other end 3T.
Form 12A. At one end 3T of the conductive plate 1B, one connecting portion 13 is formed, and at the other end 3T, an external terminal 13A as the other connecting portion is formed. The openings 5, 5A, 5B are located on the left of the short piece 3S of the annular body 3,
It is formed at the center and right, and the external terminals 11 and 13A and the connecting portions 11
A, 12, 12A and 13 are formed to protrude from the peripheral edge 3F of the short piece 3S.

Then, the conductive plates 1, 1A, 1B are overlapped with each other, and an insulating sheet 21 is arranged between them to insulate each other. The insulating sheet 21 has a thickness of, for example, several tens of microns. In the conductive plate 1, the external terminal 11 has a vertically extending portion 111 bent downward and a grounding portion 112 having a lower portion of the vertically extending portion 111 horizontally bent outward, and one of the other connecting portions is provided. 11A forms a protruding portion 111A protruding from the peripheral edge 3F of the short piece 3S.
The tip of 11A is formed by bending upward. The conductive plate 1
A, the one connecting portion 12 is connected to the lower connecting portion 11.
A is provided at a position corresponding to A, and the tip of a protruding portion 121 protruding from the peripheral edge 3F is formed by bending upward, and the protruding portion 111A has a thickness ( On the other hand, the other connecting portion 12A forms a projecting portion 121A projecting from the peripheral edge 3F of the short piece 3S, and the tip of the projecting portion 121A is bent upward. It becomes. In the conductive plate 1B, the one connecting portion 13 is provided at a position corresponding to the lower connecting portion 12A, and is formed by bending a tip of a protruding portion 131 protruding from the peripheral edge 3F upward, The protruding portion 121A is formed longer than the protruding portion 131 by the thickness of the connecting portion 12A, while the external terminal 13A is formed by a downwardly bent vertical portion.
131A and a ground portion 132A obtained by bending a lower portion of the vertical portion 131A outward and horizontally. The height of the external terminal 13A is such that the insulating sheets 21, 21 are provided between the conductive plates 1, 1A, 1B. The grounding portion 132A and the grounding portion 112 are set to be the same in a state of being sandwiched and superposed. The insulating sheet 21 has a hollow portion 21A that is narrower than the hollow portion 4, and its outer periphery is formed wider than the peripheral edge 3F of the annular body 3. The short piece 21S and the long piece 21L of the insulating sheet 21 are The ring 3 is formed wider than the short piece 3S and the long piece. Also, as shown in FIG. 7, the lower other connecting portion 11A and the upper one connecting portion 12A
Are connected to each other, and the distal end 11S side of the lower connecting portion 11A and the side surface of the upper connecting portion 12 are connected by a connecting portion 22 such as solder or welding, so that the connecting portion 11A and the connecting portion 12 are electrically connected. While being connected, the upper and lower conductive plates 1 and 1A are integrated,
Similarly, the lower connecting portion 12A and the upper connecting portion 13 are overlapped and connected by the bonding portion 22.

As shown in FIG. 5, the conductive plate 2 on the secondary side
One end 3T has an external terminal 14 which is one connection part.
Is formed, and a connection portion 14A is formed at the other end 3T.
At one end 3T of the conductive plate 2A, an external terminal 15A as the other connecting portion is formed. The openings 6 and 6A are formed on the left and right of the short piece 3S of the annular body 3, and the external terminal 1
4 and 15A and the connecting portions 14A and 15 are formed on the periphery 3 of the short piece 3S.
It is formed to protrude from F.

On the upper and lower sides of the superposed primary conductive plates 1, 1A, 1B, the secondary conductive plates 2A, 2 are superposed in an insulated state via the insulating sheets 21, 21. Is done. In the conductive plate 2, the external terminal 14 has a vertically extending portion 141 bent downward and a grounding portion 142 having a lower portion of the vertically extending portion 141 horizontally bent outwardly, and one of the other connecting portions. 14A is a protruding portion protruding from the peripheral edge 3F of the short piece 3S.
141A is formed, and the tip of the projection 141A is bent upward. In the conductive plate 2A, the one connecting portion 15 is provided at a position corresponding to the lower connecting portion 14A, and is formed by bending a tip of a protruding portion 151 protruding from the peripheral edge 3F upward, The projecting portion 141A is formed longer than the projecting portion 151 by the thickness of the connecting portion 14A,
On the other hand, the external terminal 15A is provided with a vertical portion 151 bent downward.
A and a grounding portion 152A obtained by bending the lower portion of the vertical portion 151A outward and horizontally. The height of the external terminal 15A is determined by the insulating sheets 21, 21, 21, 21 and the conductive plates 1, 1A, In the state where the conductive plates 2A and 2 are overlapped from above and below with respect to
2A and the ground part 142 are set to be the same. Also, in the same manner as the connection between the other lower connection portion 11A and the upper one connection portion 12 shown in FIG.
14A and the upper one connecting portion 15 are overlapped to form a joining portion 22.
Connected by

On the conductive plates 2, 1, 1A, 1B, 2A which are superposed on each other in an insulating state by the insulating sheet 21, the insulating sheets 21 are further disposed above and below the conductive plates 2, 1, 1A, 1B, 2A. A pair of cores 31, 31 are incorporated, and the core 31 is made of a magnetic member.
3 and 33, and a central portion 34 inserted between the side walls 33 and 33 and inserted into the hollow portions 4, 21A.

Next, the method of manufacturing the transformer will be described. Each of the conductive plates 1, 1A, 1B, 2, 2A is formed by punching an annular body 3 including a plate piece forming an external terminal and a connecting portion. I do. For example, in the case of the conductive plate 1,
The annular body 3, the external terminal 11 and the connecting portion 11A are punched out of one copper plate. Next, as shown in FIG. 4, the external terminal 11 and the connection portion 11A are formed by bending. Similarly, each of the conductive plates 1A, 1B,
2, 2A are formed. Next, on the primary side, the insulating sheets 21, 21 are sandwiched between the conductive plates 1, 1A, 1B, and the annular members 3 are superposed in a state where they are insulated from each other. As a result, the upper and lower corresponding connection portions 11A, 12 and 12A
And the connecting portion 13 come into contact with each other, and are joined by the joining portions 22 and 22, respectively. As a result, a primary assembly 35 in which the primary conductive plates 1, 1A, 1B are integrated is formed, and the external terminal 11, the lower annular body 3, the connecting portion 11A, the connecting portion 12, and the inner annular body are formed. 3, the connecting portion 12A, the connecting portion 13, the upper annular body 3, and the external terminal 13A form a continuous winding structure in this order. Further, on the secondary side, only the interval H at which the primary side assembly 35 can be inserted is provided.
When the upper and lower conductive plates 2A and 2 are separated from each other,
14A and the connecting portion 15 are joined by the joining portion 22 to form a secondary assembly 36 in which the secondary conductive plates 2 and 2A are integrated,
A winding structure that is continuous with the external terminal 14, the lower annular body 3, the connecting portion 14A, the connecting portion 15, the upper annular body 3, and the external terminal 15A is formed by the conductors 2 and 2A on the secondary side.

Then, the primary assembly 35 is inserted between the secondary assemblies 36 from the thickness direction to assemble them, and the cores 31, 31 are assembled from above and below the primary assembly 35, as shown in FIG. The transformer 37 is obtained, and the grounding portions 112, 132A, 142, 15A of the external terminals 11, 13A, 14, 15A are located on the same plane. Then, the primary side conductive plates 1, 1A, 1B are connected in a superposed state to form a winding structure, and similarly, the secondary side conductive plates 2, 2A are superposed on the primary side. By forming the winding structure, the overall height can be suppressed and the conductor occupancy can be set to 50 to 60%.

As described above, in the present embodiment, the openings 5, 5A, 5A,
5B, 6 and 6A are formed to provide ends 3T and 3T, and connecting portions 11, 11A, 12, and 12 are provided on the ends 3T and 3T.
Primary side with A, 13,13A, 14,14A, 15,15A and 2
The conductive plates 1, 1A, 1B, 2, 2A on the secondary side are formed, and at least one of the conductive plates 1, 1A, 1B, 2, 2A on the primary side and the secondary side is used in a plural number (this embodiment Then
(A plurality of conductive plates are used for both the primary side and the secondary side.) The primary side and the secondary side conductive plates 1, 1A, 1B, 2, 2A are superposed in an insulated state, and the plurality of sides are used. Conductive plate 1, 1
A, 1B, 2, 2A are connected to one connecting portion 12,
Since 13 and 15 are connected to the other connecting portions 11A, 12A and 14A of the lower conductive plate, the primary and secondary sides use substantially flat conductive plates 1, 1A, 1B, 2, and 2A. The conductor occupancy can be improved, and the current loss can be reduced by adjusting the thickness of the conductive plates 1, 1A, 1B, 2, 2A having a winding structure to the current to be used.

Further, as described above, in this embodiment, claim 2
Corresponding to the plurality of conductive plates 1, 1A, 1B
Are the external terminals 13A and 11 as the uppermost other connecting portion and the lowermost one connecting portion, and the plurality of conductive plates 2 and 2A are the uppermost other connecting portion. And the one connection part at the bottom was made external terminals 15A and 14,
By connecting the connecting portions directly to the substrate or the like as the external terminals 11, 13A, 14, 15A, the conductive plates 1, 1A, 1B, 2,
The heat on the 2A side can be efficiently radiated to the substrate side, which is suitable for using a relatively large current. Then, the grounding portions 112, 132A of the external terminals 11, 13A, 14, 15A,
If 142 and 15A are soldered to an external substrate or the like, the heat radiation can be further improved.

As described above, according to the third embodiment, since the connecting portions 11A, 12, 12A, 13, 14A, and 15 are formed to be bent at the upper and lower sides, the plate piece is folded. The connection portions 11A, 12, 12A, 13, 14A, and 15 can be easily formed by bending.

As described above, in this embodiment, the first and second conductive plates 1 and 1 overlapped with each other.
A, 1B, 2, 2A are provided with cores 31, 31,
1, 31 and primary and secondary conductive plates 1, 1A, 1B, 2,
2A, it can be applied to a large current, and is suitable for a so-called power transformer.

As described above, in the present embodiment, the conductive plates 1, 1A, 1B, 2, and 2A have a substantially quadrangular shape, and the conductive plates on the primary side and the secondary side are overlapped with each other. Board 1,1
A, 1B, 2, 2A are connection parts 11, 11A, 12,
Since 12A, 13, 13A, 14, 14A, 15, 15A are arranged on different sides, the connection parts 11, 11A, 12, 12A, 13, 13 on the primary side are arranged.
A gathers and the secondary side connection parts 14, 14A, 15,
Since 15A is gathered, the connection work between the connection parts on each side becomes easy.

As described above, according to the present embodiment, the conductive plates 1, 1A, 1B, 2, 2A have a substantially rectangular shape, and the primary and secondary conductive plates are overlapped with each other. Plate 1,
1A, 1B, 2, 2A are connection parts 11, 11A, 1 respectively.
2,12A, 13,13A, 14,14A, 15,15A are arranged on the opposite short sides 3S, 3S, so the connection part on each side
The connection work between 11, 11A, 12, 12A, 13, 13A, 14, 14A, 15, 15A is easy, and the conductive plate has no protrusion on one long side. Can be manufactured.

As described above, in the present embodiment, the conductive plates 1, 1A, 1B, 2, 2
Since the insulating sheet 21 is arranged between A, the insulating structure can be simplified and the manufacturing can be performed easily.

As described above, in this embodiment, a plurality of primary conductive plates 1, 1A, and 1B, which are one of the primary and secondary conductive plates, are overlapped with each other. Since the other conductive plates 2A and 2 are overlapped on the upper and lower sides of the one conductive plate 1, 1A and 1B,
By inserting a plurality of superposed conductive plates 1, 1A, 1B between 2A, assembly can be performed, and manufacturing becomes easy.

The present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention. For example, in the embodiment, the surface mount transformer has been described as an example, but the present invention can be applied to various inductance elements. In addition, one of the primary side and the secondary side may use only one conductive plate. In the embodiment, three primary sides and two secondary sides have been described. However, it goes without saying that more may be used. No. Furthermore, the thickness of the conductive plate can be changed between the primary side and the secondary side depending on the use conditions.

[0040]

According to the first aspect of the present invention, an opening is formed in a part of a flat plate-shaped annular body to provide an end, and a connecting part is provided at the end side of the primary side and the secondary side. Side conductive plate is formed, and at least one of these primary side and secondary side conductive plates is used in plurality, and the primary side and secondary side conductive plates are overlapped in an insulated state, and The conductive plate is one in which one connection portion of the upper conductive plate is connected to the other connection portion of the lower conductive plate, and the conductor occupancy can be improved,
An inductance element capable of reducing current loss can be provided.

According to a second aspect of the present invention, the conductive plate on the plurality of sides uses the other connection part at the top and the one connection part at the bottom as an external terminal, and is connected to the outside. It is possible to provide an inductance element that has a simple structure, can improve the conductor occupancy, and can reduce current loss.

According to a third aspect of the present invention, there is provided an inductance element in which the connection portion is bent at one of the upper and lower sides, so that the conductor occupancy can be improved and the current loss can be reduced. it can.

According to a fourth aspect of the present invention, there is provided an inductance element in which a core is provided on the superposed primary and secondary conductive plates, whereby the conductor occupancy can be improved and the current loss can be reduced. Can be provided.

According to a fifth aspect of the present invention, the conductive plate has a substantially rectangular shape, and the primary and secondary conductive plates are arranged on different sides in a superposed state. Thus, it is possible to provide an inductance element that can improve the conductor occupancy and reduce the current loss.

According to a sixth aspect of the present invention, the conductive plate has a substantially rectangular shape, and the primary and secondary conductive plates are arranged such that the respective connection portions are arranged on opposite short sides in an overlapping state. In addition, it is possible to provide an inductance element that can improve the conductor occupancy and reduce current loss.

According to a seventh aspect of the present invention, there is provided an inductance element in which an insulating sheet is arranged between the superposed conductive plates, whereby the conductor occupancy can be improved and the current loss can be reduced. .

According to an eighth aspect of the present invention, a plurality of one of the primary side and the secondary side conductive plates are overlapped, and the other conductive plate is overlapped above and below one of the stacked conductive plates. In addition, it is possible to provide an inductance element that can improve the conductor occupancy and reduce current loss.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing one embodiment of the present invention.

FIG. 2 is a perspective view of a primary-side conductor according to the first embodiment;

FIG. 3 is a perspective view of a secondary-side conductor according to the first embodiment;

FIG. 4 is a perspective view of a primary-side conductor before assembling.

FIG. 5 is a perspective view of a secondary-side conductor and an insulating sheet before assembling.

FIG. 6 is a perspective view of the same assembling state.

FIG. 7 is a cross-sectional view illustrating the joining of the connection parts.

[Explanation of symbols]

 1, 1A, 1B conductor (primary side conductive plate) 2, 2A conductor (secondary side conductive plate) 3 annular body 3S short piece 11 external terminal (one connection part) 13A external terminal (the other connection part) 12, 13, 15 Connections (one connection) 14 External terminals (one connection) 15A External terminals (the other connection) 11A, 12A, 14A Connections (the other connection) 21 Insulation sheet 31 core

Claims (8)

[Claims] An opening is formed in a part of a flat plate-shaped annular body to provide an end portion, and a primary side and a secondary side conductive plate provided with a connecting portion at the end side are formed. A plurality of at least one of these primary side and secondary side conductive plates,
The primary and secondary conductive plates are superposed in an insulated state,
The inductance element, wherein the plurality of conductive plates on one side have one connection portion of an upper conductive plate connected to the other connection portion of a lower conductive plate. 2. The inductance element according to claim 1, wherein the conductive plate on the plurality of sides uses the other connection part at the top and the one connection part at the bottom as external terminals. 3. The inductance element according to claim 1, wherein the connection portion is formed to be bent at one side in the upper and lower directions. 4. The inductance element according to claim 1, wherein a core is provided on the superposed primary and secondary conductive plates. 5. The conductive plate according to claim 1, wherein said conductive plate has a substantially quadrangular shape, and said primary and secondary conductive plates have their connection portions arranged on different sides in a superposed state. The inductance element according to any one of the above. 6. The conductive plate according to claim 1, wherein the conductive plate has a substantially rectangular shape, and the primary and secondary conductive plates are arranged on the opposite short sides in a superposed state. The inductance element according to any one of claims 1 to 4. 7. The inductance element according to claim 1, wherein an insulating sheet is arranged between the superposed conductive plates. 8. The semiconductor device according to claim 1, wherein one of the primary and secondary conductive plates is overlapped with a plurality of conductive plates, and the other conductive plate is overlapped above and below one of the stacked conductive plates. The inductance element according to any one of claims 1 to 7.