JP2002353041A - High voltage transformer, discharge lamp lighting device and floodlight - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem of a high voltage auto-transformer that the winding ratio of primary and secondary windings and the cross-sectional area of winding for ensuring a large quantity of current cannot be ensured and the size of the transformer is increased. SOLUTION: The high voltage transformer comprises a coil winding 21 formed by filling the winding slots 15 of a coil spool 13 with conductor paste and then solidifying the paste, and an insulation case 17 provided, on the inner surface thereof, with spiral protrusions 19 being fitted in the winding slots 15 where the coil winding 21 is formed. The coil spool 13 on which the coil winding 21 is formed is then fixed to the outer circumferential surface of a ferrite core 12 and the spiral protrusions 19 of the insulation case 17 are screwed into the spiral winding slots 15 of the coil spool 13 thus ensuring the insulation creeping distance on the outer surface of the coil spool 13 applied with the coil winding 21.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a high-voltage transformer for generating a high voltage to be supplied to a high-pressure discharge lamp, a floodlight lamp and the like during lighting control, and a discharge lamp using the high-voltage transformer. It relates to a lighting device and a light emitting device.

[0002]

2. Description of the Related Art Conventionally, a headlight lamp for an automobile or a projection lamp of a video projector for enlarging and projecting a television image on a screen, for example, a metal halide lamp type high-pressure discharge lamp includes an instantaneous lighting start-up and an after-lighting. Stable lighting maintenance is required.

For this purpose, a high-pressure discharge lamp is provided with a high-voltage generating device for generating a high-voltage pulse at the time of starting operation, and a lighting circuit controlled so that a large power is supplied at the time of starting and a fast start-up is performed. A kidding lighting device is used.

[0004] A lighting device for a high-pressure discharge lamp is disclosed in an application specification already filed by the present applicant. The circuit configuration of the lighting device of the high-pressure discharge lamp disclosed in the above-mentioned patent application will be described with reference to FIGS.

[0005] Incidentally. FIG. 4 is a block diagram showing the overall configuration of the discharge lamp lighting device, and FIG. 5 is a block diagram showing the configuration of a lighting circuit of the discharge lamp lighting device. This lighting device will be described taking a lighting device of a headlight lamp of an automobile as an example.
In addition, DC indicated by reference numerals in the figure is a DC power supply, EO
C is a lighting circuit device, IG is a high-voltage transformer, and IB is a high-pressure discharge lamp.

[0006] The DC power source DC is a 12V battery of an automobile. As shown in FIG. 5, in the lighting circuit device EOC, SW1 is a power switch, C1 is an electrolytic capacitor,
C is a lighting circuit, and CC is a control means. The power switch SW1 is connected to a DC power source DC and a lighting unit OC described later.
, And controls the blinking of the high-pressure discharge lamp IB. The electrolytic capacitor C1 is connected to the power switch SW1
Is connected in parallel with the DC power supply DC.

The lighting means OC includes a switching regulator DC / DC and an inverter DC / AC. Switching regulator DC / DC
It mainly comprises an output transformer T, switching means Q1, a gate drive signal generation circuit GDG, a diode D1, and a smoothing capacitor C2. The primary winding wp of the output transformer T and the switching means Q1 are connected in series between both ends of the electrolytic capacitor C1. The switching means Q1 comprises a MOSFET. The resistor R1 inserted in series with the switching means Q1 is
For detecting switching current. The gate drive signal generation circuit GDG generates a gate drive signal and applies it between the gate and the source of the switching means Q1. The gate drive signal can be PWM-controlled according to a control signal input from the outside. A diode D1 and a smoothing capacitor C2 are connected in series to both ends of the secondary winding ws of the output transformer T.

The output transformer T has a tertiary winding wt.
, One end of which is grounded, and the other end on the high voltage side is input to the high voltage transformer IG as a DC output line t1 via a diode D. Then, a boosted and controlled DC output voltage of the switching regulator DC / DC is obtained between both ends of the smoothing capacitor C2.

The inverter DC / AC comprises a full-bridge type inverter and comprises four switching means Q2.
To G5, gate drive circuits GDC1 to GDC4, rectangular wave oscillation circuit OSC, switching means SW2, inverting circuit N and non-inverting circuit Y.

The four switching means Q2 to Q5
Are composed of MOSFETs and are connected so as to form a bridge circuit. The input terminal of the bridge circuit is connected between the DC output terminals of the switching regulator DC / DC. Gate drive circuit GDC1
To GDC4 form a gate drive signal in synchronization with an output signal or a DC potential of a rectangular wave oscillation circuit OSC, which will be described later, via an inverting circuit N or a non-inverting circuit Y. A gate drive signal is supplied between the gate and the source to turn them on. The square wave oscillation circuit OSC has a frequency of 100 Hz to 2 k.
It oscillates a square wave output signal of Hz. Switching means SW2
Connects the output signal of the rectangular wave oscillation circuit OSC and the DC potential selectively to the gate drive circuits GDC1 and GDC4 via the inversion circuit N, and connects the gate drive circuits GDC2 and GDC3 to the non-inversion circuit Y. Connected through.

The output of the square wave oscillation circuit OSC is applied to the gate drive circuits GDC1 to GDC4 via the switching means SW2 and the inverting circuit N or the non-inverting circuit Y, so that Q2 and Q out of the four switching means.
5 and Q3 and Q4 are alternately switched to perform an inverter operation, and an AC output voltage is obtained from an output terminal of a bridge circuit formed by them. Further, when the DC potential is applied to the gate drive circuits GDC1 to GDC4 via the switching means SW2 and the inverting circuit N or the non-inverting circuit Y, Q2 and Q5 of the four switching means are turned on, and Q3 and Q4 are turned on. Since it is turned off, a DC output voltage is obtained from the output terminal of the bridge circuit.

That is, when either the DC output or the AC output is selected, the lighting circuit EOC connects its main power lines t2 and t3 to the discharge lamp lamp IB via the high voltage transformer IG. Thus, this can be lit in DC or AC.

The control means CC includes a lamp voltage detector LV.
D, a lamp current detection unit LCD, a lighting detection unit LD, a lamp power control unit LPC, and a DC lighting time control unit DCC. The lamp voltage detection unit LVD is composed of a series circuit of a pair of resistors R2 and R3 connected between both ends of a smoothing capacitor C2 for obtaining a DC output voltage of the switching regulator DC / DC, and a discharge lamp is connected between both ends of the resistor R3. A voltage proportional to the lamp voltage of the lamp IB is obtained.

The lamp current detecting unit LCD includes a DC output of a switching regulator DC / DC and an inverter D
A resistor R inserted in series between the DC input terminals of C / AC
4, the voltage drop across resistor R4 is proportional to the lamp current.

The lighting detector LD includes a lamp voltage detector LV.
Responds to the D detection output. That is, the high pressure discharge lamp I
At the start of discharge, B becomes a lamp voltage at which the voltage appearing between its electrodes is clearly lower than the no-load voltage appearing before. Therefore, the lighting detector LD is provided with a lamp voltage detector L
By monitoring the detection output of VD, it is possible to detect that the high-pressure discharge lamp IB has been turned on when the detection output has suddenly decreased.

The lamp power control unit LPC includes a target lamp power calculation circuit TO, an actual lamp power calculation circuit AO, and a differential amplifier circuit DA. The target lamp power calculation circuit TO previously stores the target supply lamp power with respect to the initial value as table data in the memory, and calculates the target supply lamp power according to the DC voltage application time calculated according to the turn-off time.

The actual lamp power calculation circuit AO obtains the actual supply lamp power actually supplied to the high-pressure discharge lamp IB by calculation based on the detection outputs of the lamp voltage detector LVD and the lamp current detector LCD.

The differential amplifier circuit DA receives the target supply lamp power calculated by the target lamp power calculation circuit TO and the actual supply lamp power calculated by the actual lamp power calculation circuit AO. The difference is output as a control input of the gate drive signal generation circuit GDG.

The DC lighting time control unit DCC includes a light-off time timer LOT, an initial value setting circuit IVS, a counter CT, and a DC lighting time timer DVT.

The turn-off time timer LOT is provided by a lighting detector LD.
Is monitored, and when the output disappears, it is determined that the light is turned off, the operation is started, and the light-off time is measured. In addition,
The turn-off time timer LOT is configured to continue operating even when the power switch SW1 is turned off by the built-in battery.

The initial value setting circuit IVS stores in advance the initial value of the counter CT with respect to the light-off time, that is, the counter initial value in the memory as table data, and gives an initial value corresponding to the light-off time to the counter CT described later. .

The counter CT sends an initial value to a DC lighting time timer DVT and a target lamp power calculation circuit TO based on the detection output of the lighting detection section LD. And
The counter operation is started, and the operation time is stored in advance in the memory as table data according to the counter initial value output from the initial value setting circuit IVS, and the DC voltage application time determined according to the counter initial value is determined. The operation is continued during.

The DC lighting time timer DVT starts counting time based on the detection output of the lighting detection unit LD.
The DC lighting time is stored in advance in the memory as table data according to the counter initial value, and the switching means SW2 is switched to the lower side in FIG. 5 during the DC lighting time determined by the counter initial value. When the counter output from the counter CT reaches the DC lighting additional time, the switching means SW2 is switched to the upper side in FIG.

In the high-voltage transformer IG, as shown in FIG. 4, a primary winding 7b and a secondary winding 7c of a pulse transformer 7 are connected in series with additional polarity. Other circuit components include a charge / discharge capacitor C3, a switch G, and a bypass capacitor C4. The charge / discharge capacitor C3 is connected between the output lines t1 and t3, and is charged by a direct current whose half-wave rectified by the diode D causes an induced voltage generated in the tertiary winding wt of the output transformer T of the switching regulator DC / DC. Is done. The switch G is constituted by a discharge gap, and when the terminal voltage reaches the discharge starting voltage, the switch G is discharged and acts to turn on the switch. The charge / discharge capacitor C3, the switch G, and the primary winding 7b of the pulse transformer 7 form a closed circuit, and thus constitute a relaxation oscillation circuit. Therefore, when the switch G is turned on, the charge of the charge / discharge capacitor C3 flows in the primary winding 7b of the pulse transformer 7 in a pulsed manner, and a high-voltage pulse voltage is induced in the secondary winding 7c, and the discharge lamp lamp IB Since the voltage is applied between the pair of electrodes 2, 2, the starting of the discharge lamp IB is promoted.

As described above, a high-voltage transformer IG that generates a high-voltage pulse at the start of lighting of a discharge lamp is used. Since the high-voltage transformer IG generates an output voltage exceeding 10 KV and is installed in the vicinity of the high-pressure discharge lamp IB, it is required to reduce its size.

In order to secure the output voltage of 10 KV or more and to reduce the size, the windings of the high-voltage transformer IG are wound back into a plurality of winding grooves provided in the winding frame in a plurality of layers. Can obtain the desired output voltage most reliably. However, if these multiple rewinding windings are used, it is necessary to ensure sufficient interlayer insulation of the windings, and the transformer for high voltage becomes large, or if the interlayer insulation cannot be sufficiently secured, reliability is impaired. Also. For this reason, a simple single-layer winding is generally used.

On the other hand, in order to obtain a high voltage output, a high winding ratio, that is, a step-up ratio is secured to the high voltage transformer IG, and a large current after the high pressure discharge lamp is turned on is supplied to the high voltage transformer IG. It is necessary to secure a current capacity for the operation.

Since this current capacity is proportional to the cross-sectional area of the wire of the winding, if the single-layer winding of the high-voltage transformer is formed by using a wire having a round cross-section, the step-up ratio is secured. Therefore, there is a problem that the transformer shape becomes longer because the number of turns cannot be reduced, and the current capacity cannot be secured if the wire diameter of the winding wire is reduced due to the small size.

For this purpose, a wire having a flattened cross-sectional shape, usually a rectangular wire, or a wire called an edgewise wire is used.

[0030]

Conventionally, high-voltage transformers have been required to have a boost ratio for generating a high-voltage pulse at the time of starting a high-pressure discharge lamp and a current capacity for maintaining lighting.

In order to secure the boost ratio and the current capacity and to reduce the size, a wire having a flat cross section is used for the winding. However, this flat wire is
In the current technology, there is a problem that the cross-section becomes square, the insulating coating on the edge portion of the cross-section is very easily damaged, and the work efficiency at the time of winding around the bobbin is reduced.

When a high-voltage transformer is produced using this flat wire, the flat wire cannot be directly wound around a winding frame having a plurality of winding grooves divided by a flange portion. Using a jig having the same shape as that described above, the coil is shaped into a wound coil, and then an insulating resin is sealed therein. Since the distance between the wires of the coil wound by the jig using the flat wire is relatively narrow, the insulating resin cannot sufficiently penetrate between the windings, and there is a problem that it is difficult to maintain insulation. .

The present invention provides a high-voltage transformer which can be reduced in size and which can sufficiently secure a boost ratio and a current capacity. It is an object of the present invention to provide a discharge lamp lighting device and a light projecting device.

[0034]

A high-voltage transformer according to the present invention comprises a ferrite core and an insulating member.
A coil winding frame having a spirally formed winding groove on an outer peripheral surface thereof, and a plurality of conductive particles in the winding groove of the coil winding frame; A coil winding formed in a spiral shape in a solidified state; and an insulating case formed on an inner surface with a spiral protrusion fitted into the winding groove of the coil winding frame formed with the coil winding. When;
It is characterized by having.

In the present invention and each of the following inventions, the definitions and technical meanings of terms are as follows unless otherwise specified.

The ferrite core is a magnetic path of a magnetic flux generated by using a Ni—Zn ferrite material or the like and windings wound around the ferrite material. The ferrite core is formed, for example, in a substantially cylindrical shape, and a primary winding and a secondary winding are wound around the cylindrical outer periphery. A power supply is connected to the primary winding. A load is connected to the secondary winding.
A high voltage output is obtained by the turn ratio (step-up ratio) of the primary winding and the secondary winding.

The coil bobbin is formed of an insulating material, is formed in a substantially cylindrical shape so as to be disposed on the outer periphery of the ferrite core, and has a winding wire around which a winding wire is wound. A wire groove and a flange for electrically insulating and isolating the wire groove from each other are formed, and the wire groove and the collar are formed in a spiral shape.

A conductor paste, which will be described later, is embedded and solidified in the groove for winding of the coil winding frame to form a spiral coil winding in the groove for winding.

The conductor paste is obtained by pulverizing a conductor into a particle state, and mixing the conductor particles with an adhesive, a sintering material, a photo-curing agent and the like to form a paste. After embedding this conductive paste in the winding groove portion of the coil winding frame, by sintering or irradiating with light, the conductor particles of the conductor paste are connected to each other in the winding groove portion. The resulting coil winding is formed.

The amount of the conductive paste embedded and solidified in the concave groove portion for winding is embedded to fill the entire width of the concave groove portion for winding. The upper part of the flange part which divides between the concave groove parts is buried leaving a predetermined dimension. Thereby, the coil winding formed of the conductor paste has a rectangular cross-sectional shape having a width dimension of the winding groove and a vertical dimension having a height embedded in the winding groove.
A relatively large cross-sectional area ensuring a large current capacity can be obtained.
In addition, the distance between the coil windings is a distance via a flange provided between the coil windings, and the creepage distance between the winding start end and the winding end of the winding coil should be large. Becomes possible.

In this connection, terminals are implanted in the conductive paste at both ends of the coil winding formed in the groove for winding of the coil winding frame, or lead wires are formed at both ends where the conductive paste is solidified. Are connected by soldering or the like to form terminals.

The insulating case electrically insulates the outer peripheral portion of the coil winding formed of the conductive paste embedded and solidified in the winding groove of the coil winding frame. The insulating case has a substantially cylindrical shape, and has a spirally formed convex portion that fits with the concave groove portion for winding on the inner peripheral surface. The height of the spiral convex portion formed on the inner peripheral surface of the insulating case comes into contact with the surface of the coil winding which is formed by embedding a conductor paste in the groove for winding of the coil winding frame and solidifying. It is set to the position dimension.

As a result, the insulation case is screwed into the upper opening of the recessed groove portion and the flange portion where the conductive paste is not embedded, so that the insulation between the coil windings is formed. Can be easily formed, and the creepage distance between the winding start end and the winding end end of the winding coil can be sufficiently ensured.

The groove for winding of the coil winding frame is set to 1
By dividing and setting for the secondary winding and for the secondary winding,
A primary winding coil and a secondary winding coil can be formed simultaneously, or a coil winding made of a conductive paste provided on the coil winding frame is used as a secondary winding coil, and the secondary winding coil is insulated. A winding groove is formed on the outer peripheral surface of the insulating case in the same manner as the coil winding frame, and a conductor paste is embedded and solidified in the winding groove of the insulating case to form a primary winding coil. It can also be formed.

The high-voltage transformer having such a structure can be downsized, a winding ratio (step-up ratio) for obtaining a high-voltage pulse at the time of starting a discharge lamp or the like can be secured, and a coil winding made of a conductive paste can be used. Since the cross section of the wire can be flattened, a large current capacity after starting the discharge lamp can be secured, and the efficiency of the manufacturing and assembling work is improved.

According to a second aspect of the present invention, there is provided a high-voltage transformer comprising: a ferrite core; and a spiral winding groove directly formed on an outer peripheral surface of the ferrite core. A conductor paste is formed in the winding groove. A coil winding formed by embedding and solidifying; and an insulating case having an inner surface formed with a helical protrusion fitted and screwed into the winding groove on the outer peripheral surface of the ferrite core. And

A groove for winding is formed directly on the outer peripheral surface of the ferrite core, and the conductor paste is embedded and solidified in the groove for winding of the ferrite core. Form a coil winding.

The coil winding is insulated by screwing the projection of the insulating case into the winding groove formed with the coil winding formed on the outer peripheral surface of the ferrite core.

This makes it possible to further reduce the size of the high-voltage transformer, secure the creepage distance between the winding start end and the winding end end of the winding coil, and increase the winding ratio (step-up) for obtaining a high-voltage pulse. Ratio) and a flat cross section for a large current can be easily formed.

According to a third aspect of the present invention, there is provided a high-voltage transformer according to any one of the first and second aspects, wherein the insulating case is formed of the same member as the ferrite core. And a closed magnetic circuit is constituted.

The insulating case has electrical insulation properties and is formed of the same ferrite material as the ferrite core formed of the Ni-Zn ferrite material.
A coil winding provided on the coil bobbin according to claim 1,
Alternatively, the leakage magnetic flux of the coil winding directly provided on the ferrite core according to claim 2 can be effectively used by the closed magnetic path of the insulating case formed of the ferrite material.
Further, it becomes easier to secure the high voltage pulse and the large current capacity and to downsize the transformer.

A high-voltage transformer according to a fourth aspect of the present invention is the high-voltage transformer according to any one of the first to second aspects, wherein the coil is formed in the concave groove for the winding instead of the insulating case. Apply insulation paint on the outer surface of the winding,
The outer surface of the coil bobbin on which the coil winding is formed is insulated by the insulating paint.

The insulating paint contains an electrical insulating material in the paint. When the insulating paint is applied and dried and cured, an insulating layer is formed.

The surface of the coil winding obtained by embedding and solidifying a conductive paste in the groove for winding provided on the outer peripheral surface of the coil winding frame or the ferrite core with the insulating paint and the groove for winding is formed. An insulating layer of a coil winding is generated instead of the insulating case by applying and curing the opening of the flange portion where the conductor paste is not embedded.

The insulating layer formed by applying the insulating paint is most effective when the ferrite core is a prism and the coil winding frame is a rectangular tube.

As a result, it is possible to further reduce the size while maintaining the high voltage pulse and the large current capacity.

According to a fifth aspect of the present invention, there is provided a high-voltage transformer according to any one of the first to fourth aspects, wherein the winding groove has a width smaller than a width of the groove. The depth dimension of the concave groove is increased.

The shape and dimensions of the groove for winding of the coil winding frame or the groove for winding provided on the ferrite core are as follows:
By making the depth dimension L3 of the winding groove groove larger than the width dimension L1 of the winding groove groove (L1 <L3), it is formed of a conductor paste embedded and solidified in the winding groove groove. By making the cross section of the coil winding to be substantially rectangular and flat, a large current capacity can be ensured, and the conductor pace is not embedded in the opening of the winding groove. Thereby, the surface creepage distance between the windings of the coil winding can be secured.

As a result, the insulation creepage distance between the start and end of the winding coil can be sufficiently secured while maintaining the high voltage pulse and the large current capacity.

According to a sixth aspect of the present invention, there is provided a discharge lamp lighting device comprising: the high-voltage transformer according to any one of the first to fifth aspects;
A stabilizing means for stabilizing a DC power supply and a DC power supply stabilized by the stabilizing means are converted into an AC power supply in order to supply a lighting starting power supply and a lighting maintaining power supply to the high-voltage transformer. A high-voltage discharge lamp connected to an output of the high-voltage transformer; and a high-voltage discharge lamp connected to an output of the high-voltage transformer. It is characterized in that the transformer is converted into a predetermined high voltage to control the lighting of the discharge lamp.

The discharge lamp is, for example, a metal halide lamp-type high-voltage discharge lamp having at least a light-transmitting hermetic container provided with a pair of electrodes, first and second introduction lines, and a discharge medium. is there.

At the start of lighting, this discharge lamp supplies a high voltage pulse to both electrodes to promote discharge, and when the discharge is started, the discharge lamp is lit and maintained by a large current.

The lighting circuit is a circuit device for controlling the lighting of the discharge lamp, and includes a stabilizing means for stabilizing a DC power supply and an inverter means for converting the DC power stabilized by the stabilizing means into an AC power supply. The AC power converted by the inverter means is used to generate a high-voltage pulse at the time of starting lighting by the high-voltage transformer and to control a current supply at the time of maintaining lighting.

As a result, stable starting and sustaining of the discharge lamp can be achieved.

According to a seventh aspect of the present invention, there is provided a light projecting device according to any one of the first to fifth aspects, wherein the high-voltage transformer is supplied with a lighting starting power source and a lighting maintaining power source. Stabilizing means for stabilizing the DC power supply,
And a lighting circuit comprising inverter means for converting DC power stabilized by the stabilizing means into AC power and supplying the AC power to the high-voltage transformer; and a floodlight connected to the output of the high-voltage transformer. Wherein the AC power output from the lighting circuit is converted into a predetermined high voltage by a high-voltage transformer to control the lighting of the discharge lamp.

The floodlight is, for example, an automobile headlamp or a floodlight of a projector for projecting a television image on an enlarged screen. This flood lamp is relatively similar to the discharge lamp, and supplies a high voltage pulse to promote discharge between the electrodes in the lamp, and when the discharge is started, it is lit and maintained by a large current. It has become. The lighting circuit is substantially the same as the lighting circuit used in the sixth aspect of the present invention.

With this light emitting device, it is possible to reliably start lighting and maintain stable lighting.

[0068]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 is an exploded cross-sectional view showing a configuration of an embodiment of a high-voltage transformer according to the present invention. FIG. 2 illustrates the relationship between a coil winding frame, a coil winding, and an insulating cover of the high-voltage transformer of the present invention. The cross-sectional view
FIG. 3 is a plan view illustrating the coil winding of the high-voltage transformer according to the present invention.

Referring to FIG. 1, high-voltage transformer 1 of the present invention will be described.
1 will be described. This high-voltage transformer 11
A substantially columnar ferrite core 12, this ferrite core 1
The coil winding frame 13 includes a substantially cylindrical coil winding 13 having a hollow portion 14 into which the second coil 2 is inserted, and a substantially cylindrical insulating case 17 having a hollow portion 18 penetrating the outer periphery of the coil winding frame 13.

On the outer peripheral surface of the coil winding frame 13, winding groove portions 15 and flange portions 16 are alternately formed at predetermined intervals. The winding groove 15 and the flange 16 are
It is formed spirally like a male screw.

On the inner peripheral surface of the hollow portion 18 of the insulating case 17, a convex portion 19 is formed spirally like a female screw. The projection 19 of the insulating case 17 is formed to be screwed into the winding groove 15 of the coil winding frame 13.

The relationship between the coil winding frame 13, the coil winding 21, and the insulating case 17 will be described with reference to FIGS. The groove 15 for winding of the coil winding frame 13
Has a width L1 and a depth L3 in a substantially rectangular cross-sectional shape, and the width L1 of the winding groove 15 and the width of the flange 16 are substantially the same. The width dimension of the portion 16 is L2, that is, the spiral pitch of the winding groove portion 15 is L2.
It is formed so that it becomes. The depth L3 of the winding groove 15 is larger than the width L1 (L1 <
L3).

For example, when the outer diameter of the coil winding frame 13 is 30
mmφ, the axial length is 20 mm, the width L1 of the winding groove 15 is 0.1 mm, the width L1 of the winding groove 15 and the helical pitch L2 formed by the flange 16 are 0.2 mm, The depth L3 of the groove 15 is 3.5 mm.

The dimension L4 from the bottom surface of the concave groove portion 15 for winding of the coil winding frame 13 formed in such a shape and dimension is as follows.
A conductor pace is embedded to a position of 0 mm, and the embedded conductor paste is solidified.

That is, the height L4 of the winding groove 15
When the conductor paste is buried and solidified to a position of = 3.0 mm, a spiral single-layer wound coil 21 having a cross section of L1 × L4 and a helical pitch of L2 can be formed as shown in FIG. FIG. 3 shows the coil winding 21 formed of a conductive paste on the coil winding frame 13 without the coil winding frame 13.

The conductive paste is obtained by mixing conductive particles, which are obtained by pulverizing a conductive material into particles, with an adhesive and a sintering material or a photo-curing material to form a paste. After embedding in 15, a conductor layer is formed by sintering and solidifying in a furnace or by photo-curing by projecting ultraviolet rays.

When using a material that allows the conductor paste to be sintered and solidified, the material of the coil winding frame 13 is:
A ceramic material is used.

That is, the coil winding frame 13 having the above-described shape and dimensions is used.
By solidifying the conductive paste embedded in the concave groove portion 15 for winding, the cross-sectional width L1 = 0.1 mm and the height L
With 4 = 3.0 mm, the coil winding 21 with 100 turns can be formed with a helical pitch L2 = 0.2 mm.

On the other hand, the embedding height of the conductive paste 21 is set to L4 with respect to the height L3 of the winding groove 15, so that the opening of the winding groove 15 has:
L3 (3.5 mm) -L4 (3.0 mm) = 0.5 mm
The opening of the winding groove 15 remains. The distance between the remaining opening of the winding groove 15 and the upper surface of the adjacent conductive paste is the width L2 (0.2 mm) of the flange 16.
-L1 (0.1 mm) = 0.1 mm, the remaining dimension of the flange 16 on the left and right side surfaces of the upper surface of the conductive paste is 0.5 mm
A creepage distance of 1.1 mm obtained by adding × 2 = 1.0 mm can be secured.

In other words, the creepage distance between the starting end and the ending of the coil winding 21 in which the conductive paste is buried to the full depth of the winding groove 15 of the coil winding frame 13 is determined by the total length of the coil winding frame 13. Although the dimension is 20 mm, as in the present invention, when a remaining portion of 0.5 mm is provided at the opening of the concave groove portion 15 for winding, the creepage distance between the start end and the end of the coil winding 21 is as described above. A creepage distance of about 110 mm, which is obtained by multiplying the distance between the windings of one winding coil by 1.1 mm by the number of windings of 100, can be secured.

On the other hand, on the inner peripheral surface of the hollow portion 18 of the insulating case 17, an opening (L3-L4) of the coil winding frame 13 in which the conductor paste is embedded and solidified to form the coil winding 21 is formed. Is formed.
The width of the projection 19 fits into the width L1 of the winding groove 15 and has a spiral pitch L2, and the height of the projection 19 is Opening (L
3-L4). That is,
The space L5 is provided so that the height of the protrusion 15 does not come into contact with the upper part of the coil winding 21 of the conductor paste embedded and solidified. This space L5 becomes an insulating gap.

As a result, a sufficient creepage distance and insulation between the winding start end and the winding end end of the coil winding 21 in which the conductive paste is embedded and solidified in the winding groove portion 15 can be sufficiently ensured, and high The size of the voltage transformer 11 can be reduced.

Next, another embodiment of the present invention will be described.
A winding groove similar to the winding groove 15 provided on the coil winding frame 13 is directly engraved on the outer peripheral surface of the ferrite core 12 using a laser processing device or the like. Is generated in a shape in which a winding groove similar to the winding groove 15 is provided on the outer peripheral surface of the ferrite core 12.

The coil paste 21 is formed by embedding and solidifying the above-described conductive paste in the groove for winding formed directly on the outer peripheral surface of the ferrite core 12. After generating a coil winding directly on the ferrite core 12, the insulating case 1
7 is screwed into the groove for winding provided on the outer periphery of the ferrite core 12 to insulate the coil winding.

As a result, it is possible to further reduce the size of the high-voltage transformer.

Further, by forming the material of the insulating case 17 using the same kind of material as the ferrite core 12, the insulating case 17 becomes a closed magnetic circuit, and the leakage of the coil winding 21 generated by the conductive paste is prevented. The magnetic flux can be effectively used, and the transformer performance of the high-voltage transformer 11 can be improved.

Further, instead of the insulating case 17, the conductor paste 21 is embedded and solidified in the winding groove 15 of the coil winding frame 13, and the ferrite core 12 is hollowed out of the coil winding frame 13. After fitting to the part 14, the outer peripheral surface of the coil winding frame 13 is coated with an insulating paint. That is, the outer peripheral portion of the coil winding 21 made of the conductive paste formed in the concave groove portion 15 for the winding, the opening portion where the conductive paste 21 is not embedded in the concave groove portion 15 for the winding, and the head of the flange portion 16. The part is applied with the insulating paint.

As a result, the creepage distance between the starting end and the end of the coil winding 21 formed of the conductive paste can be ensured in the same manner as described above, and the insulation of the coil winding frame 13 is facilitated. Can be further downsized.

In each of the above-described embodiments of the present invention, the start and end terminals of the coil winding 21 are connected to the starting end of the coil winding 21 formed by the conductive paste in the winding groove 15. Concave winding groove 15 corresponding to the end
Is formed by embedding a terminal to be connected to the conductive paste in the wide winding groove portion 15 or by connecting a terminal or a terminal lead wire by soldering or the like.

Further, the winding groove for the primary winding and the groove for the secondary winding are integrally provided in the axial direction of the coil winding frame 13 or the coil winding frame 13 is A primary winding and a secondary winding are divided and formed, and the divided primary winding coil winding and secondary winding coil winding are mounted on the ferrite core 12, or The coil winding frame 13 is formed as a secondary winding, and the primary winding is wound and insulated on the outer peripheral surface of the insulating case 17 which is screwed to the outer peripheral surface of the coil winding frame 13. It is possible to form primary and secondary windings of a voltage transformer.

Further, the high-voltage transformer 11 of the present invention can be used for a lighting device of a discharge lamp or a lighting device of a floodlight lamp. That is, it can be used as the high-voltage transformer IG of the lighting device shown in FIGS. Thereby, in the vehicle headlight, when the lighting device is arranged at a limited installation location of the headlamp and at a limited installation location, the size of the high-voltage transformer is reduced, so that the lighting device is located close to the installation location of the headlamp. The arrangement of the lighting device became possible. In a projector,
It was possible to reduce the size of the lighting device of the floodlight, which contributed to the downsizing of the entire projector.

[0092]

The high voltage transformer according to the first aspect of the present invention
By embedding and solidifying the conductive paste in the winding groove of the coil winding frame, a flat single-layer coil winding can be generated, miniaturizing and obtaining a high voltage pulse at the time of starting a discharge lamp or the like. And increase in the winding ratio (boosting ratio) of the coil, and the cross-section of the winding coil formed of the conductive paste can be flattened to ensure a large current capacity after starting the discharge lamp, and the efficiency of manufacturing and assembling work. It has the effect of improvement.

The high-voltage transformer according to the second aspect of the present invention can further reduce the size of the high-voltage transformer by directly generating a coil winding made of a conductive paste on the ferrite core, and can further reduce the winding of the coil winding. The creepage distance between the start end and the winding end can also be ensured, and there is an effect that a winding ratio and a large current capacity for obtaining a high voltage pulse can be easily ensured.

The high-voltage transformer according to the third aspect of the present invention uses a ferrite material for the insulating case on the outer periphery of the coil winding so that a closed magnetic path is formed and the magnetic flux can be effectively used, and a high-voltage pulse and a large current capacity can be obtained. And the size of the transformer can be further easily reduced.

The high-voltage transformer according to the fourth aspect of the present invention maintains the high voltage pulse and the large current capacity by insulating both the winding coil and the flange with insulating paint instead of the insulating case. In addition, there is an effect that the size can be further reduced.

According to a fifth aspect of the present invention, in the transformer for winding a high voltage, the depth of the groove is larger than the width of the groove, so that the groove is embedded in the groove. By making the cross section of the coil winding formed of the solidified conductive paste into a substantially rectangular flat shape, the insulation creepage distance between the beginning and end of the coil winding is maintained while maintaining the high voltage pulse and large current capacity. Has the effect of being able to secure sufficient.

A discharge lamp lighting device according to a sixth aspect of the present invention uses the lighting circuit using the high-voltage transformer according to any one of the first to fifth aspects, whereby a stable lighting start of the discharge lamp is achieved. This has the effect that the lighting can be maintained and the lighting device can be downsized.

According to a seventh aspect of the present invention, a lighting circuit of a floodlight lamp is formed by using the high-voltage transformer according to any one of the first to fifth aspects, so that a reliable lighting start-up is achieved. This has the effect of enabling stable lighting maintenance and miniaturization.

[Brief description of the drawings]

FIG. 1 is a developed cross-sectional view showing a configuration of an embodiment of a high-voltage transformer according to the present invention.

FIG. 2 is a cross-sectional view illustrating a relationship between a coil winding frame, a coil winding, and an insulating cover of the high-voltage transformer according to the present invention.

FIG. 3 is a plan view illustrating a coil winding generated by a conductor paste of the high-voltage transformer according to the present invention.

FIG. 4 is a block diagram showing the overall configuration of a conventional discharge lamp lighting device.

FIG. 5 is a block diagram showing a configuration of a lighting circuit of a conventional discharge lamp lighting device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 ... High voltage transformer 12 ... Ferrite core 13 ... Coil winding frame 14 ... Hollow part 15 ... Concave groove part for winding 16 ... Flange part 17 ... Insulating case 18 ... Hollow part 19 ... Convex part 21 ... Coil winding

Claims (7)

[Claims] A ferrite core and an insulating member;
A coil winding frame having a spirally formed winding groove on an outer peripheral surface thereof, and a plurality of conductive particles in the winding groove of the coil winding frame; A coil winding formed in a spiral shape in a solidified state; and an insulation formed on an inner surface of a spiral projection fitted into the winding groove of the coil winding frame formed with the coil winding. A high-voltage transformer comprising: a case; 2. A ferrite core, and a coil formed by directly forming the spiral winding groove on the outer peripheral surface of the ferrite core, and embedding and solidifying the conductive paste in the winding groove. A high-voltage transformer, comprising: a winding; and an insulating case having an inner surface formed with a helical projection fitted and screwed into the winding groove on the outer peripheral surface of the ferrite core. 3. The height according to claim 1, wherein the insulating case is made of the same material as the ferrite core, and the insulating case forms a closed magnetic circuit. Transformer for voltage. 4. An insulating paint is applied on the outer surface of the coil winding formed in the groove for the winding instead of the insulating case, and the coil winding is formed by the insulating paint. The high-voltage transformer according to any one of claims 1 to 2, wherein an outer surface of the coil winding frame is insulated. 5. The height according to claim 1, wherein a depth of the groove is greater than a width of the groove. Transformer for voltage. 6. A high-voltage transformer according to claim 1, wherein a DC power supply is stabilized in order to generate and supply a lighting start-up power supply and a lighting-maintaining power supply to the high-voltage transformer. A lighting circuit comprising: stabilizing means; and inverter means for converting DC power stabilized by the stabilizing means into AC power and supplying the AC power to the high-voltage transformer;
And a high-voltage discharge lamp connected to the output of the high-voltage transformer. The high-voltage transformer converts the AC power output from the lighting circuit into a predetermined high voltage to control the lighting of the discharge lamp. Discharge lamp lighting device characterized by the above. 7. A high-voltage transformer according to any one of claims 1 to 5, wherein the DC power supply is stabilized in order to generate and supply a lighting start-up power supply and a lighting-maintaining power supply to the high-voltage transformer. A lighting circuit comprising: stabilizing means; and inverter means for converting DC power stabilized by the stabilizing means into AC power, and supplying the AC power to the high-voltage transformer;
A floodlight connected to the output of the high-voltage transformer;
A lighting device, comprising: converting an AC power output from the lighting circuit into a predetermined high voltage by a high-voltage transformer to control lighting of the floodlight lamp.