JP2002184637A - Electromagnetic device and its manufacturing apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily manufacture an electromagnetic device and at a low cost by attaching a former-wound coil to a toroidal core. SOLUTION: In an electromagnetic device a toroidal core 1 having a gap 3 is wound by a coil, the gap 3 is formed in a manner such that the former- wound coil on the gap 3 is fitted externally in the toroidal core 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic device such as a pulse transformer or a high voltage transformer having a coil wound around a toroidal core, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Some electromagnetic devices such as a high-voltage transformer have a toroidal core wound with a primary coil and a secondary coil (for example, Japanese Utility Model Application Laid-Open No. 7-18408). In this type of conventional electromagnetic device, since the toroidal core has a ring shape, it is difficult to externally fit the coil wound around the toroidal core. There is also an electromagnetic device in which a gap 82 is provided in the toroidal core 81 as shown in FIG. 9, but this gap 82 is formed by cutting a part of the toroidal core 81 in the circumferential direction in the radial direction. In this case, too, it was difficult to fit the coil wound around the gap 82 into the toroidal core 81.

Therefore, conventionally, even when the gap 82 is formed in the toroidal core 81, the primary coil n1 and the secondary coil n2 are all wound directly around the toroidal core 81.

[0004]

Therefore, in the conventional case,
It is necessary to directly wind all the coils wound around the toroidal core by one turn (turn) on the toroidal core, and in particular, the secondary coil n2 having a large number of turns is wound on the toroidal core 81 by one turn (turn). Since the winding is very troublesome, the manufacture of the electromagnetic device is very troublesome and the manufacturing cost is high. SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has been made in such a manner that a coil wound around a toroidal core can be mounted, so that an electromagnetic device can be manufactured easily and inexpensively.

[0005]

The technical means of the present invention for solving this technical problem is as follows. In an electromagnetic device in which a coil is wound around a toroidal core 1 having a gap 3, The gap 3 is formed in such a manner that a coil wound around the gap 3 can be externally fitted into the toroidal core 1. Further, another technical means of the present invention is that the gap 3 is provided in a direction substantially in contact with the inner peripheral surface 1a of the toroidal core 1.

Further, another technical means of the present invention resides in that the inner peripheral surface 1a of the toroidal core 1 is formed in a flat surface. Another technical means of the present invention is a method of manufacturing an electromagnetic device in which a coil n2 is wound around a toroidal core 1, wherein a gap 3 is formed around the toroidal core 1, and a coil n2 wound around the gap 3 is formed. The point lies in fitting into the toroidal core 1 so as to fit outside. Another technical means of the present invention is a method for manufacturing an electromagnetic device in which a primary coil n1 and a secondary coil n2 are wound around a toroidal core 1, wherein a gap 3 is formed in the toroidal core 1,
The secondary coil n2 wound around the gap 3 is fitted to the toroidal core 1 so as to be fitted outside, and the primary coil n
1 is wound directly around the toroidal core 1.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. FIGS. 1 to 5 show an embodiment of the present invention. As shown in FIG. 1, the toroidal core 1 is formed of a nickel-based insulator core, and has a smaller number of turns than the toroidal core 1. The transformer main body (electromagnetic device main body) 2 is configured by winding the coil n1 and the secondary coil n2 having a large number of turns. The primary coil n1 and the secondary coil n2 are respectively wound around the toroidal core 1 in a single-layer winding without forming a gap between one end portions. A toroidal core 1 is provided between the other end portions of the primary coil n1 and the secondary coil n2.
Is formed.

As shown in FIG. 4, the inner peripheral surface 1a of the toroidal core 1 is formed in a flat surface, and the outer peripheral surface 1b of the toroidal core 1 is formed in a convex shape protruding radially outward. A gap 3 is formed in a part of the toroidal core 1 in the circumferential direction. This gap 3 is the toroidal core 1
Is formed in a part of the circumferential direction of the toroidal core 1 by cutting a part in the circumferential direction with a diamond cutter 5 or the like shown in FIG. 2, and the gap 3 substantially contacts the inner circumferential surface 1 a of the toroidal core 1. Direction, so that the wound coil can be externally fitted to the toroidal core 1 from the gap 3.

The secondary coil n2 having a large number of windings is formed into a toroidal core 1 by using a rod-shaped jig 6 shown in FIG. Wound around the core 1. The primary coil n1 having a small number of turns is wound around the toroidal core 1 by being directly wound around the toroidal core 1. As shown in FIG. 5, the jig 6 corresponds to the cross-sectional shape of the toroidal core 1, and one surface 6a of the jig 6 corresponding to the inner surface 1a of the toroidal core 1 is formed in a flat surface. The other surface 6b of the jig 6 corresponding to the outer surface 1b of the core 1 is formed in a convex shape.

As shown in FIG. 1, the transformer main body 2 is stored in a storage case 9. The storage case 9 is formed in a rectangular parallelepiped shape having a substantially square bottom surface, and a concave groove 11 having a ring-shaped opening surface is formed on one bottom surface, and the transformer body 2 is stored in the concave groove 11. A pair of terminal pins 12 and 13 are implanted at one corner of the bottom surface of the storage case 9 where the concave groove 11 is formed, and a primary coil n1 guided through the guide groove 14 to the terminal pins 12 and 13. Are connected in a state where both end portions are entangled. Here, the transformer main body 2 is arranged so that the gap 3 side of the toroidal core 1 is located at a position close to the terminal pins 12 and 13.

A terminal pin 16 is implanted at the center of the bottom surface of the storage case 9 where the concave groove 11 is formed, and the terminal pin 16 has one terminal of a secondary coil n2 guided through a guide groove 17. The connection is made with the end portions entangled.
The other end of the secondary coil n2 is connected to the terminal pin 12 while being entangled. Groove 1 in storage case 9
At the other corner of the bottom surface where 1 is formed, three fixing pins 1
9 are implanted, and the fixing pins 19 are used for fixing when mounted on a wiring board or the like. Groove 1 in storage case 9
1, a holding hole 20 is drilled in a portion of the secondary coil n2 corresponding to the vicinity of the terminal portion connected to the terminal pin 16, and a temperature fuse 21 is formed in the holding hole 20.
Is inserted. An opening window 23 is formed in a portion of the holding hole 20 on the concave groove 11 side, and
It can contact the next coil n2. The thermal fuse 21 detects the temperature of the secondary coil n2, and detects an increase in current due to a rise in the temperature of the secondary coil n2. The thermal fuse 21 is inserted at an appropriate place in the circuit so as to cut off the circuit when the current is abnormally increased. Here, the reason why the thermal fuse 21 is arranged near the end of the secondary coil n2 is that the largest stress is generated at this portion when the secondary coil n2 is wound, and the temperature rise is most likely to occur during energization. Because.

When the above-mentioned electromagnetic device is manufactured, as shown in FIG. 2, a part of the toroidal core 1 in the circumferential direction is cut by a diamond cutter 5 or the like, so that a gap 3 is formed in the part of the toroidal core 1 in the circumferential direction. Is formed so that the wound coil can be externally fitted to the toroidal core 1 from the gap 3. Next, as shown in FIG. 3, the secondary coil n2 having a large number of windings is model-wound using a rod-shaped jig 6, and the secondary coil n2 thus formed is wound around the toroidal core 1 with a gap 3 thereof. The secondary coil n <b> 2 is wound around the toroidal core 1. On the other hand, the primary coil n1 is directly wound around the toroidal core 1 by one turn (turn), and the primary coil n1 is wound around the toroidal core 1.

The primary coil n is attached to the toroidal core 1.
The transformer main body 2 configured by winding the primary and secondary coils n2 is housed in the housing case 9 and the terminal pins 12 and
13 is connected to both end portions of the primary coil n1, terminal pins 16 are connected to one end portion of the secondary coil n2,
The other end of the secondary coil n2 is connected to the terminal pin 12. Therefore, according to the above-described embodiment, it is possible to easily fit the wound coil into the toroidal core 1 from the gap 3, and accordingly, the secondary coil n2
Is wound around the toroidal core 1 and the secondary coil n2 having a large number of turns is turned (turned) for one turn.
This eliminates the need for direct winding on the toroidal core 1 by one, making the manufacture of the electromagnetic device very simple and reducing the manufacturing cost.

If the gap 3 formed by cutting a part of the toroidal core 1 in the circumferential direction is too large, FIG.
By joining another ferrite core 25 as shown in (1), the gap 3 can be easily reduced. FIGS. 7 and 8 show another embodiment. As shown in FIG. 7, of the components constituting the discharge lamp lighting circuit having the configuration shown in FIG. And an air-core choke coil CH is housed in an empty space of the housing case 9. The discharge lamp lighting circuit includes a ballast Ba for limiting an AC power supply AC such as a commercial AC power supply. A series circuit of a capacitor C1 and a resistor R1 is connected between output terminals of the ballast Ba. On the other hand, switch element SW-choke coil CH-primary coil n1 of pulse transformer PT
Are connected in parallel, and a series circuit of a secondary coil n2-discharge lamp DL of a pulse transformer PT is connected in parallel to a series circuit of a capacitor C1 and a resistor R1. As the switch element SW, a Sidac or the like that is turned on when the voltage across the capacitor C1 becomes equal to or higher than a predetermined value when the power is turned on and the capacitor C1 is charged through the resistor R1 is used. That is, the choke coil CH, the pulse transformer PT, the capacitor C
1, the resistor R1, and the switch element SW constitute an igniter.

When the switch element SW is turned on, the electric charge of the capacitor C1 is released through the primary coil n1 of the choke coil CH and the pulse transformer PT. A high voltage corresponding to the turn ratio between the primary coil n1 and the secondary coil n2 of the pulse transformer PT is generated between both ends of the secondary coil n2, and the discharge lamp DL is turned on. Here, the choke coil CH serves to reduce a sudden change in current when the capacitor C1 is discharged, and has a function of reducing stress on the switch element SW.

In the above configuration, the choke coil CH is wound around a coil bobbin 31 having four lead terminals 30a to 30d.
b is connected to both ends of the choke coil CH, and the choke coil CH is not connected to the remaining two lead terminals 30c and 30d. In the pulse transformer PT, the portion where the terminal portions of the primary coil n1 and the secondary coil n2 are commonly connected needs to be connected to the ballast Ba and the capacitor C1, and therefore, to the lead terminal 30c not connected to the choke coil CH. Connecting. In addition, the pulse transformer P
One end of the primary coil n1 of T is connected to one end of the choke coil CH, and is therefore connected to the lead terminal 30b. One end of the secondary coil n2 of the pulse transformer PT connected to the discharge lamp DL is connected to a terminal pin 23 implanted in the storage case 9.
Connected to.

As described above, the choke coil CH is stored in the storage case 9 of the pulse transformer PT, and some of the terminals of the pulse transformer PT also serve as the lead terminals 30b and 30c of the choke coil CH. The insulation distance can be secured in a small space, and the size can be reduced. The other points are the same as those in the above embodiment. Therefore, also in the case of this embodiment, it is possible to easily fit the coil wound into the toroidal core 1 from the gap 3, and therefore, the secondary coil n2 having a large number of turns is wound around the toroidal core 1 to form the toroidal core. Core 81
, It is not necessary to directly wind the secondary coil n2 around the toroidal core 1 by one turn (winding).

In the above embodiment, the primary coil n
The secondary coil n having the larger number of turns among the primary and secondary coils n2
2 is wound around the toroidal core 1 by being wound around the toroidal core 1 from the gap 3 by molding and the primary coil n1 is wound around the toroidal core 1 directly. However, instead of this, both the primary coil n1 and the secondary coil n2 are wound around the mold, and the gap 3
May be fitted around the toroidal core 1 so as to fit around the toroidal core 1 and wound around the toroidal core 1. Further, the coil wound around the toroidal core 1 is not limited to the primary coil n1 and the secondary coil n2, and the electromagnetic device to which the present invention is applied has only one kind of coil wound around the toroidal core 1. Alternatively, three or more types of coils may be wound around the toroidal core 1. In this case, at least one type of coil is wound around the toroidal core 1 and fitted into the toroidal core 1 from the gap 3. What should I do?

[0019]

According to the present invention, it is possible to easily fit a coil wound into the toroidal core 1 from the gap 3, and it is very simple to manufacture an electromagnetic device.
In addition, the manufacturing cost of the electromagnetic device is reduced.

[Brief description of the drawings]

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

FIG. 2 is a plan view showing a step of forming a gap in the toroidal core.

FIG. 3 is a plan view showing a step of winding a secondary coil n2 around the toroidal core.

FIG. 4 is a sectional view taken along line AA of FIG. 2;

FIG. 5 is a sectional view taken along line BB of FIG. 3;

FIG. 6 is a plan view of a toroidal core for explaining the same effect.

FIG. 7 is a perspective view showing another embodiment.

FIG. 8 is a circuit diagram of the same.

FIG. 9 is a perspective view showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Toroidal core 1a Inner peripheral surface 1b Outer peripheral surface 2 Transformer body (electromagnetic device main body) 3 Gap n1 Primary coil n2 Secondary coil

Claims (5)

[Claims] 1. An electromagnetic device in which a coil is wound around a toroidal core (1) having a gap (3), wherein a gap (3) is formed in the toroidal core (1) from the gap (3). Wound coil is toroidal core (1)
An electromagnetic device characterized in that it is formed so as to be fitted in an external fitting shape. 2. The electromagnetic device according to claim 1, wherein the gap is provided in a direction substantially in contact with an inner peripheral surface of the toroidal core. 3. An inner peripheral surface (1a) of the toroidal core (1).
The electromagnetic device according to claim 1, wherein the member is formed in a flat surface shape. 4. A coil (n) is provided on the toroidal core (1).
In the method for manufacturing an electromagnetic device wound with 2), a gap (3) is formed in the toroidal core (1), and a coil (n2) wound around the gap (3) is fitted around the toroidal core (1). A method for manufacturing an electromagnetic device, comprising: 5. A method for manufacturing an electromagnetic device in which a primary coil (n1) and a secondary coil (n2) are wound around a toroidal core (1), wherein a gap (3) is formed in the toroidal core (1). Then, the secondary coil (n2) wound around the gap (3) is fitted to the toroidal core (1) so as to fit outside, and
A method for manufacturing an electromagnetic device, comprising: directly winding a secondary coil (n1) around a toroidal core (1).