JP2002280225A - Flat coil, its manufacturing method and transformer simple flat coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a flat coil structure of a sandwich structure, capable of simple obtaining a duplex-winding one-turn flat coil at a low cost and a flat coil structure of a sandwich structure, capable of interposing another coil between both sides to enhance magnetic coupling to another coil. SOLUTION: A method for manufacturing the flat coil, formed by punching a metal plate comprises the steps of folding a pair of legs made of strip-like legs, extended substantially in parallel via a predetermined air gap in the width direction and a closed coil member having a pair of loop parts of substantially the same size and shape extended from both ends of the legs, so that the pair of the loops substantially coincide with each other at the folding parts and form the flat coil.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an improvement in a rectangular coil suitable for forming a thin transformer and a choke coil having a relatively large current capacity.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open Nos. Hei 6-231985 and Hei 7-220 disclose thin-film coils suitable for forming a transformer or a choke coil having a relatively large current capacity.
950, JP-A-9-7854, JP-A-9-854
As described in Japanese Patent No. 134827, a rectangular coil that is wide and thin in the radial direction of the winding is often used. It is known that a rectangular coil is suitable for a thin coil through which a large current can flow because a width in a winding direction, that is, a spiral direction is larger than a thickness.
These publications disclose a case where the number of turns of the rectangular coil is relatively large. However, for example, a power supply for an electric vehicle may have a large output current such as 12V100A. In addition, the output voltage is considerably lower than the input voltage in the power supply for communication,
In many cases, an output characteristic having a large output current is required. And as a transformer used for such a power supply, the secondary winding may usually have one turn, or at most about two to three turns to reduce copper loss,
There are quite a few uses.

[0003]

However, a rectangular coil having a relatively large number of turns has a problem that mechanical stress increases because the inner and outer diameters of the winding are considerably different. Because it is difficult, the cost is high, and it is not used much for special purposes.
Such a situation exists in the case of a rectangular coil having a relatively large number of turns. However, a one-turn rectangular coil can be easily and inexpensively manufactured by punching a metal plate with a pressing means. By connecting one or three series, a two-turn or three-turn rectangular coil can be easily manufactured.

Therefore, the present invention is based on the fact that a single-turn double-winding rectangular coil is easily and inexpensively manufactured by punching a metal plate, and the double-winding coil is not connected by using a separate terminal. A one-turn rectangular coil structure, a rectangular coil structure that can be easily formed into a sandwich structure capable of sandwiching the other coil from both sides to enhance magnetic coupling with the other coil, and two or three turns. It is an object of the present invention to provide a rectangular coil structure having a terminal portion that facilitates series connection or connection to other members.

[0005]

According to a first aspect of the present invention, there is provided a rectangular coil formed by stamping a metal plate, wherein the rectangular coil is formed by punching a metal plate and extending substantially in parallel with a predetermined gap in a width direction. A closed coil member consisting of a leg portion composed of a band-shaped leg and a pair of loop portions having substantially the same size and shape respectively extending from both ends of the leg portion, so that the pair of loop portions substantially match each other. The present invention provides a rectangular coil formed by folding the leg at the folded portion. According to the first aspect, it is possible to obtain a rectangular coil that can be densely magnetically coupled with another coil having a low connection resistance simply by folding or bending the coil deploying body punched from the metal plate.

According to a second aspect of the present invention, there is provided a rectangular coil according to the first aspect, wherein the leg portion has a terminal portion. It is not necessary to use a separate connection terminal, and an input terminal or an output terminal can be easily obtained.

According to a third aspect of the present invention, in order to solve the above problem, in the second aspect, the terminal portion has a portion bent substantially at right angles to a band-like leg of the leg portion, and the leg is provided. The present invention provides a rectangular coil that is any one of a terminal hole and a terminal pin hole formed in a portion, a screw-shaped hole and a screw-shaped terminal pin formed in the leg, or a combination thereof. It is not necessary to use a separate connection terminal, and an input terminal or an output terminal can be easily obtained.

According to a fourth aspect of the present invention, in order to solve the above-mentioned problem, in any one of the first to third aspects,
Provided is a rectangular coil in which the folded portion has a predetermined length and a predetermined gap exists between both the loop portions and between the leg portions. In this embodiment, it is possible to increase the magnetic coupling density between the coils.

A fifth aspect of the present invention is directed to any one of the first to third aspects, in order to solve the above problem.
Provided is a rectangular coil in which the folded portion is small and the folded portions of the leg portions are in contact with each other or in contact with each other via an insulator. In this embodiment, a very thin power coil can be obtained.

According to a sixth aspect of the present invention, in order to solve the above-mentioned problem, the first and second coils are formed according to any one of the first to fifth aspects. The width of the gap in the width direction is larger than the width of the band-shaped leg, and one of the band-shaped legs of each of the first and second coils is in a space between the band-shaped legs of the other coil, and the first and second coils are formed. A rectangular coil is provided in which said strip legs of two coils are alternately located. In this embodiment, the strip legs can be connected in series or in parallel with the shortest distance.

According to a seventh aspect of the present invention, in order to solve the above-mentioned problem, the first and second coils are formed according to any one of the first to fifth aspects. The strip-shaped legs provide rectangular coils that are offset from each other in the width direction. In this embodiment, the strip legs can be connected in series or in parallel with the shortest distance.

According to an eighth aspect of the present invention, in order to solve the above-mentioned problem, the first and second aspects described in the sixth or seventh aspect are provided.
Are provided in parallel or in series using the terminal portions, to provide a rectangular coil. Series connection or parallel connection can be easily performed without using a separate connection terminal.

According to a ninth aspect of the present invention, the first and second aspects described in the sixth or seventh aspect are provided to solve the above problem.
Provide rectangular coils connected in parallel or in series by short-circuit means.

According to a tenth aspect of the present invention, in a method for manufacturing a double-turn, one-turn rectangular coil, a predetermined gap is provided in the width direction from one or more stacked metal plates. Forming a closed coil member consisting of a pair of band-shaped legs extending substantially parallel to each other and a pair of loop portions having substantially the same size and shape respectively extending from both ends of the leg by punching with a press. And a step of folding the leg portion at a folded portion so that the pair of loop portions substantially coincide with each other. By simply folding or bending the coil deploying body punched from the metal plate, a rectangular coil that can be densely coupled to other coils having low connection resistance can be obtained.

According to an eleventh aspect of the present invention, there is provided a method of manufacturing a double-turn, one-turn rectangular coil in which a single or a plurality of stacked metal plates are provided with a predetermined gap in the width direction. A pair of band-shaped legs extending substantially parallel to each other, a terminal piece extending in the direction perpendicular to the leg in the middle of the leg, and a pair of substantially the same size and shape respectively extending from both ends of the leg. A step of stamping out and forming a closed coil member comprising a loop part by a press, a step of folding the leg part at a folded part so that the pair of loop parts substantially match each other, and a step of joining the terminal piece to the leg part And a step of bending the rectangular coil substantially at right angles to the rectangular coil. It is not necessary to use a separate connection terminal, and it is possible to manufacture a coil that can easily obtain an input terminal or an output terminal.

According to a twelfth aspect of the present invention, there is provided a transformer using a rectangular coil according to any one of the first to eleventh aspects, wherein the magnetic core of the transformer is formed by the loop of the rectangular coil. And the rectangular coil is a secondary winding or a primary winding of the transformer.

According to a thirteenth aspect of the present invention, there is provided a sandwich winding structure in which another coil having a center hole concentric with the loop portion is disposed in the gap of the coil according to the fourth aspect. Wherein the magnetic core of the transformer is inserted through the central hole. A power transformer with good magnetic coupling between the coils can be obtained.

According to a fourteenth aspect of the present invention, in order to solve the above problem, another coil having a central hole concentric with a loop portion of the coil on one or both surfaces of the coil according to the fifth aspect. And a transformer having a magnetic core of the transformer inserted through the central hole.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, referring to FIG.
An embodiment of a heavily wound rectangular coil will be described. FIG. 1 (A)
FIG. 1B is a view of the coil as viewed from the front, FIG. 1B is a side view of the coil viewed from the right, FIG. 1C is a side view of the coil viewed from below, and FIG. It is a figure and shows the original shape before bending a leg part and bending a terminal piece. First, the coil of the present invention is formed by punching a metal plate (not shown) such as a copper plate having a predetermined thickness by a press or the like, and as shown in FIG. Get '. The coil 1 shown in FIGS. 1A to 1C is formed by bending the coil deploying body 1 ′ at a substantially right angle at a dashed line A and further at a substantially right angle at a dashed line B.

The coil 1 is roughly divided into a leg portion 2, loop portions 3 and 4 extending in a loop form from both ends of the leg portion 2, and terminal pieces 5 and 6 extending outward on both sides of the leg portion 2. The leg 2 is composed of a pair of band-shaped legs 2a and 2b extending in parallel with each other via a gap S extending in the width direction. The folded portions 2c and 2d are provided at substantially the centers of the band-shaped legs 2a and 2b, respectively. The length of the folded portions 2c and 2d is substantially equal to the dimension between the chain lines A and B, and determines the gap width W in the thickness direction between the band-shaped legs 2a and 2b. The loop portions 3 and 4 are preferably of the same shape and the same size, and the loop portions 3 and 4 are successively bent at substantially right angles to the same side at chain lines A and B so that the center hole H is aligned with a gap width W. Will be folded back. Therefore, this rectangular coil has one turn, but has a double winding shape.

Next, the terminal strips 5 and 6 are bent substantially at right angles to the respective band-shaped legs 2 a and 2 b at the dashed line C, and further bent at substantially right angles at the dashed line D so as to face each other. As shown in FIG.
6 is L-shaped. In the gap between the loop portions 3 and 4 of the double-wound coil, another coil 2 indicated by a chain line is provided.
1 is arranged. The other coil 21 may have a known coil shape, and has a center hole H through which a magnetic leg of a transformer core (not shown) is inserted. The loop portions 3 and 4 are made of a thin insulating sheet or an insulating coating (not shown) that can secure electrical insulation
, A sandwich winding structure sandwiching another coil 21 is provided.

Furthermore, a transformer is formed by inserting a magnetic leg of a core (not shown) into the center hole H. The rectangular coil 1 is a secondary winding or a primary winding of the transformer, and the other coil 21 is When a primary winding or a secondary winding is formed, the loop 4
By appropriately setting the gap width W between the coils 1 and 4 and making the distance between the rectangular coil 1 and the other coil 21 as small as possible, the magnetic coupling between these coils can be maintained densely. is there. Therefore, according to the rectangular coil, it is possible to easily obtain a double-turn single-turn rectangular coil or a sandwich-winding transformer capable of densely coupling magnetic windings without requiring a connection step. .

Referring to FIG. 2, an embodiment suitable for forming a one-turn quadruple-shaped rectangular coil according to the present invention will be described. FIG. 2A shows the coil as viewed from the front, rightward on the paper, and downward from the paper, and FIGS.
Corresponding to FIG. 2B is a diagram for explaining one of the coils, and corresponds to FIGS. 1A to 1C. FIG.
(C) is a diagram for explaining the other coil, FIG.
(A) to (C). FIGS. 2D and 2E are views showing the respective coil expanders, and correspond to FIG. 1D. In FIG. 2, the same symbols as those used in FIG. 1 indicate corresponding members.

This rectangular coil is a combination of two coils 1 and 11 having substantially the same shape and the same size. The legs 2, 12 of the coils 1 and 11 are biased to different sides, and a gap S in the width direction between the strip legs 2a and 2b and a gap S in the width direction between the strip legs 12a and 12b. Denote strip legs 2a and 2b, strip legs 12a and 12b, respectively.
Has a width that is somewhat wider than the width of. And coil 1
The folded portion 2c is longer than the folded portion 12c of the coil 11 by the thickness of the band-like legs 12a and 12b. The folding of the legs 2 and 12 and the bending of the terminal strips 5 and 15 are the same as those in the first embodiment, and a description thereof will be omitted.

This rectangular coil is shown in FIG.
The coil expanders 1 ′ and 11 ′ shown in FIG. 2E are bent as described above, and the coils 1 and 11 shown in FIGS.
The coils 1 and 11 are combined as shown in FIG. 2 (A). In this rectangular coil,
As described above, the folded portion 2c of the coil 1 is longer than the folded portion 12c of the coil 11 by about the thickness of the band-shaped legs 12a and 12b. 13 and 14, the band-shaped leg 12b of the coil 11 is located in the gap S of the leg 2 of the coil 1, and the coil 1 is located in the gap S of the leg 12 of the coil 11.
Is located. The loop portions 3 and 13 and the loop portions 4 and 14 may be in direct contact with each other or in contact with each other via an insulating coating. Note that another coil 21 serving as a primary coil or a secondary coil of a transformer (not shown) is disposed between the loop portions 13 and 14 of the coil 11. In this embodiment, by connecting the adjacent terminal pieces 5 and 15, and 6 and 16, it is possible to easily obtain a single-turn quadruple-wound flat coil.

Referring to FIG. 3, a third embodiment which is a modification of the embodiment of FIG. 2 will be described. 3 (A), (B),
(C), (D), and (E) respectively show FIG.
(B), (C), (D), and (E). The same symbols as those used in FIG. 2 indicate corresponding members. The legs 2, 12 of the coil deployants 1 'and 11' are formed so as to be biased in different directions from each other, and the gap S between the band-shaped legs 2a and 2b and the gap S between the band-shaped legs 12a and 12b are shown in FIG.
Is considerably narrower than that of the embodiment. The coils 1 and 11 formed by folding the coil deploying bodies 1 'and 11' in the same manner as before are combined as shown in FIG. 3 (A). The loop portions 3 and 4 and the loop portions 13 and 14 substantially coincide with each other about the center hole H, and the terminal pieces 5 and 6, 15 and 16 of the same coil face each other as a pair. In this embodiment, the coils 1 and 11 are connected in series by connecting the terminal pieces 5 and 16 located inside by electrically insulating the coils 1 and 11 from each other. If each of the terminals 15 is a terminal, a thin double-turned two-turn flat coil can be easily obtained.

The embodiment shown in FIG. 4 is a modification of FIG. 1, and FIG. 4 (A) corresponds to FIGS. 1 (A) to 1 (C).
(B) corresponds to FIG. 1 (D). The same symbols as those used in FIG. 1 indicate corresponding members. This coil differs from that of FIG. 1 in that the coil is folded back at a chain line B of the coil developing body 1 'shown in FIG. In the coil 1, there is no intention to provide the folded portions 2c and 2d of a predetermined length, and the loop portions 3 and 4 are brought into direct contact with each other by being folded at the dashed line B, or come into contact with each other via an electric insulating sheet or insulating coating (not shown). In this embodiment, a sufficiently thin double-turned one-turn flat coil can be easily formed, but since the other coils 21 are arranged on either side of the flat coil 1, the magnetic coupling between the coils is made. Drops somewhat. However, if two flat coils 1 are used and the other coil 21 is sandwiched between the two flat coils, the magnetic coupling between the coils can be increased without increasing the thickness too much.

The embodiment shown in FIG. 5 is a modification of FIG. 2, and FIGS. 5A, 5B, 5C, 5D, and 5E show FIGS. ), (C), (D), and (E). The same symbols as those used in FIG. 2 indicate corresponding members. This embodiment is a combination of the coils 1 and 11 formed by folding the coil expanders 1 'and 11' at the chain line B in the same manner as the embodiment of FIG. By electrically insulating the coils 1 and 11 and selecting the connection between the terminals, a thin quad-turn 1-turn flat coil or double-turn 2-turn flat coil can be easily formed. Obtainable. For example, if the terminal strips 5 and 15 are connected to form one terminal, and the terminal strips 6 and 16 are connected to form the other terminal, a thin quadruple one-turn flat coil can be obtained. If the terminal pieces 5 and 16 are connected to each other and the terminal pieces 6 and 15 are used as terminals, a thin double-turned 2-turn flat coil can be obtained. The other coil 21 is arranged on any surface of the flat coil. According to this configuration, a very simple connection and a thin 4
It is possible to obtain a double-turn single-turn flat coil or a double-turn two-turn flat coil.

The embodiment shown in FIG. 6 is a modification of FIG. 3, and FIGS. 6 (A), (B), (C), (D) and (E) show FIGS. 3 (A) and 3 (B), respectively. ), (C), (D), and (E). The same symbols as those used in FIG. 3 indicate corresponding members. This embodiment is a combination of the coils 1 and 11 obtained by folding the coil expanders 1 'and 11' once at the chain line B in the same manner as the embodiment of FIG. . Also in this embodiment, coils 1 and 11
Is electrically insulated from each other, the terminal pieces 5 and 16 located on the inside are connected, and each of the terminal pieces 6 and 15 is a terminal. Obtained easily.

The embodiment shown in FIG. 7 is a modification of FIG. 5, and FIGS. 7 (A), (B), (C), (D) and (E) show FIGS. 5 (A) and 5 (B) respectively. , (C), (D), and (E). The same symbols as those used in FIG. 5 indicate corresponding members. In this embodiment, the coil deploying body 1 '
And 11 'are folded back at the dashed line B, and thin coils 1 and 11 having almost the same structure are combined with another coil 21 interposed therebetween. Although not shown, the coils 1 and 11 and the other coil 21 are electrically insulated. In this embodiment, since the other coil 21 is sandwiched between the coils 1 and 11, the magnetic coupling between the coils is good, and the terminals are alternately located. By electrically insulating the loop portions 3 and 4 and the loop portions 13 and 14, respectively, the terminal strip 5
And 16 are connected to each other, and the terminal strips 6 and 15 are used as terminals, respectively, to obtain a sandwich winding structure using a double-turn two-turn flat coil with good magnetic coupling. Further, similarly to the above embodiment, for example, if the terminal pieces 5 and 15 are connected to form one terminal, and the terminal pieces 6 and 16 are connected to form the other terminal, the magnetic coupling is increased and the loss is reduced. A four-turn, one-turn flat coil that can be obtained is obtained.

The embodiment shown in FIG. 8 is a modification of FIG. 6, and FIGS. 8 (A), (B), (C), (D) and (E) show FIGS. 6 (A) and 6 (B) respectively. , (C), (D), and (E). The same symbols as those used in FIG. 6 indicate corresponding members. This embodiment differs from the embodiment shown in FIG. 6 in that thin coils 1 and 11 formed by folding coil unrollers 1 ′ and 11 ′ at chain lines B are combined with another coil 21 interposed therebetween. Although not shown, the coils 1 and 11 and the other coil 21 are electrically insulated. In this embodiment, another coil 21 is connected to coils 1 and 1
Since it is sandwiched between the coils, the magnetic coupling between the coils is good, and the loss can be reduced. Since the terminal strips 5 and 6, 15 and 16 of the coils 1 and 11 are adjacently located as a pair, the loop sections 3 and 4 and the loop sections 13 and 14 are electrically insulated from each other. If the coils 1 and 11 are connected in series by connecting 5 and 16, and the terminal strips 6 and 15 are used as terminals, respectively, 2
A sandwich winding structure using a two-turn flat coil is obtained. Note that the terminal pieces 5 and 6 are as long as the gap between the coils 1 and 11 so that the terminal pieces 5 and 6 and 15 and 16 are at the same level.

The embodiment shown in FIG. 9 shows a flat coil structure using the same combination as the embodiment shown in FIG. 8 using two coils based on the embodiment shown in FIG. FIG.
(A), (B), (C), (D), and (E) correspond to FIGS. 8A, 8B, 8C, 8D, and 8E, respectively. The same symbols as those used in FIG. 8 indicate corresponding members. As can be seen from the (D) and (E), the difference between the coil developed bodies 1 ′ and 11 ′ is
And the terminal strips 5 and 6 are connected to the leg 1 of the coil developing body 11 '.
Second, they are formed longer than the terminal pieces 15 and 16. The width of the terminal strips 5 and 6 and the width of the terminal strips 15 and 16 are smaller than those of the terminals of the coil shown in FIG. As described above, the coil unfolded bodies 1 'and 11' are folded back at the chain line B, and the terminal pieces 5 and 6 and the terminal pieces 15 and 16 are further bent, so as to be shown in FIGS. Coil 1
And 11 are formed, and another coil 21 is sandwiched between the coils 1 and 11. The magnetic coupling between the coils is good as in the coil structure of FIG.

As shown in FIG. 3A, the terminal pieces 5, 6 and the terminal pieces 15, 16 are shifted in the length direction of the legs 2, 12. In this embodiment, the terminal pieces 5 and 15 and the terminal pieces 6 and 16 are connected to each other to form terminals, thereby obtaining a quadruple-turn one-turn flat coil structure. Between the loops 13 and 1 of the coil 11
4 are electrically insulated from each other, the terminal strips 5 and 16 are connected to each other, and the terminal strips 6 and 15 are used as terminals.
A flat coil structure with turns is obtained. Also in this embodiment, a sandwich winding structure using a one-turn or two-turn flat coil having good magnetic coupling can be obtained.

The embodiment shown in FIG. 10 is a modification of FIG. 8, and FIGS. 10 (A), (B), (C), (D), and (E).
Respectively represent FIGS. 6 (A), (B), (C), (D),
(E). The same symbols as those used in FIG. 6 indicate corresponding members. This embodiment is different from the embodiment of FIG. 8 in that the loop portion 13 of the coil 11 is inserted between the loop portions 3 and 4 of the coil 1 without being sandwiched between the coil 1 and the coil 11. 3, 13, 4, and 14 are combined in this order. Although not shown, the portions between the loop portions 3, 13 and 4, 14 are electrically insulated,
By connecting the terminal strips 5 and 16 and using the terminal strips 6 and 15 as terminals, a double coil two-turn flat coil structure can be easily obtained. Other coils 21 are arranged on either side of this flat coil structure, or on both sides if there are two. The terminal structure of the embodiment shown in FIGS. 1 to 10 described above is suitable for surface mounting. In the above embodiment, the terminal piece may be bent in any direction with respect to the band-shaped legs 2a, 2b as necessary, and after the bending, the terminal piece may be bent at a substantially right angle. It may be a direction. In the above embodiment, the preferred embodiment including the terminal strip has been described. However, the terminal strip does not necessarily have to be provided, and connection can be performed by soldering a lead wire or the like as in the related art. .

The embodiment shown in FIG. 11 is a modification of the terminal portion of FIG. 1, and FIGS. 11A, 11B and 11C show the embodiment shown in FIG.
This corresponds to (A), (B), and (C). The same symbols as those used in FIG. 1 indicate corresponding members. In this embodiment, terminal holes 5a and 6a are formed in each of the band-shaped legs 2a and 2b of the leg portion 2. Terminal pins 5b and 6b suitable for surface mounting are inserted into the terminal holes 5a and 6a, and soldering is performed. Fixed at. Upper surface A of the head of terminal pins 5b and 6b
Are flat for easy surface mounting.

The embodiment shown in FIG. 12 is a modified example of the terminal portion of FIG. 1, and FIGS. 12A, 12B and 12C show the terminal portion of FIG.
This corresponds to (A), (B), and (C). The same symbols as those used in FIG. 1 indicate corresponding members. In this embodiment, the terminal portion has a structure suitable for being inserted into a terminal insertion hole (not shown) of the printed circuit board. Terminal strip 5,
The distal end portion 6 is formed with narrow insertion portions 5c and 6c. The insertion portions 5c and 6c are inserted into the terminal insertion holes of the printed circuit board (not shown), and the wide terminal portion performs a stopper function, and soldering is performed at that portion.

The embodiment shown in FIG. 13 is a modified example of the terminal portion in FIG. 11, and FIGS. 13A, 13B, and 13C are similar to FIGS. 11A, 11B, and 11C. Corresponding. The same symbols as those used in FIG. 11 indicate the corresponding members.
In this embodiment, screw-shaped holes 5a 'and 6a' are formed as terminal holes in each of the band-shaped legs 2a and 2b of the leg portion 2. The illustration of the screw-shaped terminal pins screwed into the screw-shaped holes 5a 'and 6a' is omitted.

The embodiment shown in FIG. 14 corresponds to FIGS.
14A, and FIG. 14A,
(B) and (C) correspond to FIGS. 11A, 11B, and 11C or FIGS. 12A, 12B, and 12C. 11 and 1
The same symbols as the symbols used in 2 indicate the corresponding members. In this embodiment, the terminal strips 5 and 6 are bent in the direction of the surface of the drawing, and the terminal holes 5a and 6a are formed in the band-shaped legs 2a and 2b, respectively.
The terminal pins 5b and 6b are inserted and soldered. The terminal holes 5a and 6a and the terminal pins 5b and 6b are shown in FIG.
And the terminal pieces 5 and 6 have the same structure, and the description is omitted. In this embodiment, the terminal strips 5 and 6, and the terminal pins 5b and 6b can be used as terminals according to the structure of a printed board (not shown). Alternatively, both may be used as terminals as needed.

The embodiment shown in FIG. 15 is a modification of FIG. 12, and FIGS. 15 (A), (B) and (C) show the embodiment of FIG.
This corresponds to (A), (B), and (C). Considering the above-described coil developed body, the folded portions 2c and 2
d on both sides of the band-shaped legs 2a, 2b with the terminal strip 5 therebetween.
And 5 ′, terminal strips 6 and 6 ′, and folded portions 2c and 2d.
It is the one that was turned back. The terminal pieces 5 and 6 and the terminal pieces 5 ′ and 6 ′ have the same terminal structure. The terminal strips 5 and 6, and the terminal strips 5 'and 6' have narrow insertion portions 5c and 6c suitable for being inserted into terminal insertion holes of a printed circuit board (not shown) at the distal end portions, similarly to the above-described embodiment. . According to such a terminal structure, one of the terminal pieces can be connected to a printed circuit board (not shown), and the other terminal piece can be connected to an electronic component (not shown) or another printed circuit board. It is possible to give a margin to the connection. Although not shown, the insertion portions 5c and 6c of the terminal pieces 5 and 6 may be bent at right angles to either side as necessary. In this case, a terminal structure suitable for surface mounting can be provided.

The embodiment shown in FIG. 16 is a combination of the embodiment shown in FIG. 13 with terminal pieces.
(B) and (C) correspond to FIGS. 13 (A), (B) and (C). Each of the strip-shaped legs 2a, 2b is provided with screw holes 5a ', 6a' as terminal holes, and the terminal strips 5 ', 6'.
It has. The terminal strip 5 'is used so that the terminal connection using the screw holes 5a' and 6a 'and the terminal connection using the terminal strips 5' and 6 'do not short-circuit or hinder each other.
And 6 'are formed smaller than the terminal pieces of the above embodiment, and are displaced from the screw holes 5a' and 6a '. Also in this embodiment, a margin can be given to the connection of the terminals. It is to be noted that screw-like terminal pins screwed into the screw-like holes 5a 'and 6a' are not shown.

Next, the embodiment shown in FIG. 17 is a combination of the embodiments of FIGS. 13 and 14, and FIG.
(A), (B) and (C) show FIGS. 13 (A), (B),
(C) or FIGS. 14A, 14B, and 14C.
In addition to having the terminal holes 5a, 6a in each of the band-shaped legs 2a, 2b, the respective extending portions 2a 'of the band-shaped legs 2a, 2b,
2b 'is provided with screw holes 5a' and 6a '. Although the terminal pins 5b and 6b are inserted into the terminal holes 5a and 6a, illustration of terminal screws screwed into the screw holes 5a 'and 6a' is omitted. Also in this embodiment, it is possible to give a margin to the connection of the terminals. In this embodiment, threaded holes 5 are formed in the extending portions 2a 'and 2b'.
a 'and 6a' are provided, but the band-like legs 2a and 2b are made somewhat longer, and the band-like legs 2a and 2b are formed in the band-like legs 2a and 2b along the length direction thereof without providing an extending portion. May be.

The embodiment shown in FIG. 18 corresponds to FIGS.
Are combined. FIG. 18 (A),
(B) and (C) correspond to FIGS. 13 (A), (B) and (C) or FIGS. 15 (A), (B) and (C).
And threaded holes 5a ', 6a'. Since these shapes and functions are the same as those of the above-described embodiment, description thereof will be omitted. Also in this embodiment, it is possible to give a margin to the connection of the terminals. In order to make the terminal structure suitable for surface mounting,
The terminal pieces 5 and 6 may be bent inward or outward so as to face each other at a right angle from the middle.

An embodiment of a double-turn two-turn rectangular coil will be described with reference to FIG. In the embodiment of FIG. 3, the respective strip legs 2a, 2b, 12a, 1
2b is provided with terminal strips 5, 6, 15, and 16, but in this embodiment, only the outermost band-shaped legs 2b and 12a have terminal strips 6 and 15, respectively, and the inner band-shaped legs are positioned. 2a12b has no terminal strip. Strip-shaped legs 2a, 1
2b is connected by short-circuit means 30 such as a short bar. Low connection resistance between the short-circuit means 30 and the band-shaped legs 2a, 12b and mechanical fixing are ensured by soldering. By connecting the strip-shaped legs 2a and 12b by the short-circuit means 30, a double-turn two-turn rectangular coil having the terminal pieces 6 and 15 as terminals can be obtained. Alternatively, the band-shaped legs 2a and 12b may be formed so as to overlap each other, and may be welded by resistance welding, plasma arc welding, or the like without using the short-circuit means 30.

Note that, in addition to the above-described embodiments, combinations of the various terminal structures and changes in shapes may be considered, but those that include the basic configuration of the present invention are included in the scope of the present invention. Of course. Further, when making a coil unfolded body, it is of course possible to closely contact a plurality of metal plates such as a copper plate having a predetermined thickness and to punch a plurality of sheets at once by pressing or the like. It may be coated with. Furthermore, in the above embodiment, 2
Although the description has been given of the single-turn double-turn two-turn rectangular coil, three double-turn one-turn rectangular coils are connected in series in the same manner as described above, and the double-turn three-turn rectangular coil is connected in series. It is also possible to use a coil. The loop portion is shown as having a circular shape, but may have a polygonal shape if necessary.

[0045]

As described above, according to the present invention, it is possible to obtain a double-turn, single-turn rectangular coil simply and inexpensively without connecting separately, and to provide a coil between other coils. A rectangular coil structure having a sandwich structure that can sandwich the other coil from both sides to enhance magnetic coupling can be obtained. Further, a combination of these rectangular coils can easily provide a double-turned two-turn or three-turn rectangular coil.

[Brief description of the drawings]

FIG. 1 shows an embodiment of a rectangular coil according to the present invention.

FIG. 2 shows another embodiment of the rectangular coil according to the present invention.

FIG. 3 shows another embodiment of the rectangular coil according to the present invention.

FIG. 4 shows another embodiment of the rectangular coil according to the present invention.

FIG. 5 shows another embodiment of the rectangular coil according to the present invention.

FIG. 6 shows another embodiment of the rectangular coil according to the present invention.

FIG. 7 shows another embodiment of the rectangular coil according to the present invention.

FIG. 8 shows another embodiment of the rectangular coil according to the present invention.

FIG. 9 shows another embodiment of the rectangular coil according to the present invention.

FIG. 10 shows another embodiment of the rectangular coil according to the present invention.

FIG. 11 shows another embodiment of the rectangular coil according to the present invention.

FIG. 12 shows another embodiment of the rectangular coil according to the present invention.

FIG. 13 shows another embodiment of the rectangular coil according to the present invention.

FIG. 14 shows another embodiment of the rectangular coil according to the present invention.

FIG. 15 shows another embodiment of the rectangular coil according to the present invention.

FIG. 16 shows another embodiment of the rectangular coil according to the present invention.

FIG. 17 shows another embodiment of the rectangular coil according to the present invention.

FIG. 18 shows another embodiment of the rectangular coil according to the present invention.

FIG. 19 shows another embodiment of the rectangular coil according to the present invention.

[Explanation of symbols]

1, 11 ··· rectangular coil 2 ··· leg of rectangular coil 1 2a, 2b ··· band-like leg 2c of leg 2 of rectangular coil 1 · 2d ··· folded part of rectangular coil 1・ Loop portion of rectangular coil 1, 5 ′, 6, 6 ′ Terminal piece 5 a, 6 a of rectangular coil 1 Terminal hole 5 b, 6 b of rectangular coil 1 Terminal pin of rectangular coil 1 5a ', 6a', screw holes of rectangular coil 1 5c, 6c, insertion portions of terminal pieces 5, 6, of rectangular coil 1 Legs of rectangular coil 11, 12a, 12b, rectangular Strip-shaped legs 12c, 12d of leg portion 12 of coil 11 Folded portion of rectangular coil 1 13, 14 ... Loop portion of rectangular coil 11, 15, 16 ... Terminal piece of rectangular coil 11 21. Coil 30, short-circuit means

Claims (14)

[Claims] 1. A rectangular coil formed by stamping a metal plate, comprising: a pair of band-shaped legs extending substantially in parallel in a width direction through a predetermined gap; and substantially extending from both ends of the legs. A closed coil member comprising a pair of loop portions having the same size and shape is formed by folding the leg portion at a folded portion so that the pair of loop portions substantially match each other. Square coil. 2. The rectangular coil according to claim 1, wherein a terminal portion is formed on the leg portion. 3. The terminal according to claim 2, wherein the terminal portion includes a terminal piece having a portion bent substantially at right angles to the band-shaped leg of the leg portion, a terminal hole formed in the leg portion, and a terminal hole formed in the leg portion. Any of the formed screw holes,
Or a combination thereof. 4. The method according to claim 1, wherein the folded portion has a predetermined length, and a predetermined gap exists between both the loop portions and between the leg portions. Rectangular coil. 5. The flat panel according to claim 1, wherein the folded portion is small, and a folded portion of the leg portion is in contact with a contact portion or an insulator. Square coil. 6. The first and second coils formed in any one of claims 1 to 5, wherein a gap in the width direction between the band-shaped legs of the legs of the coils is larger than the width of the band-shaped legs. One of the band-shaped legs of each of the first and second coils is in a gap between the band-shaped legs of the other coil, and the band-shaped legs of the first and second coils are alternately positioned. A rectangular coil characterized in that: 7. A pair of band-shaped legs of the leg portions of the first and second coils formed in any one of claims 1 to 5, wherein the pair of band-shaped legs of the coils are mutually offset in the width direction. A rectangular coil characterized in that: 8. The first device according to claim 6, wherein
And the second coil is connected in parallel or in series using the terminal portion. 9. The first device according to claim 6, wherein
And the second coil is connected in parallel or in series by short-circuit means. 10. A method for manufacturing a double-turn, one-turn rectangular coil, comprising: a pair of band-shaped legs extending substantially in parallel in a width direction from a metal plate in which one or a plurality of metal plates are stacked with a predetermined gap therebetween. Forming a closed coil member comprising a pair of portions and a pair of loop portions having substantially the same size and shape extending from both ends of the leg portion by pressing, and the pair of loop portions substantially match each other. And a step of folding the leg portion at a folded portion. 11. A method for manufacturing a double-turn one-turn rectangular coil, comprising: a pair of band-shaped legs extending substantially in parallel in a width direction from a metal plate stacked one or a plurality thereof through a predetermined gap. A closed coil member comprising a portion, a terminal piece extending in a direction perpendicular to the leg portion in the middle of the leg portion, and a pair of loop portions having substantially the same size and shape respectively extending from both ends of the leg portion. A step of stamping and forming the terminal pieces, a step of folding the leg portions at a folded portion so that the pair of loop portions substantially match each other, and a step of bending the terminal pieces at substantially right angles to the leg portions. A method for manufacturing a rectangular coil. 12. A transformer using a rectangular coil according to any one of claims 1 to 11, wherein a magnetic core of the transformer passes through the loop of the rectangular coil, and the rectangular coil is A transformer, which is a secondary winding or a primary winding of the transformer. 13. A coil having a sandwich winding structure in which another coil having a center hole concentric with the loop portion is arranged in the gap of the coil according to claim 4, wherein a magnetic core of a transformer passes through the center hole. Transformer characterized by doing. 14. A coil having a central hole concentric with a loop portion of the coil is provided on one or both surfaces of the coil according to claim 5, and a magnetic core of the transformer is provided in the center of the coil. A transformer characterized by passing through a hole.