JP2003031422A - Coil component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil component which enough prevents the inductance value of a winding from lowering with DC superposed, realizes miniaturization, a low-loss property, saving of resources and saving of energy, and facilitates automatic manufacturing. SOLUTION: The toroidal core component is constituted such that a winding 21a is previously closely wound for a specified number of turns so that the winding width P1 is minimum to form an air-core coil, and this coil is mounted on a core 11 having a single gap 31 of a width W1 through the gap 31 and settled at the remotest position opposite away from the gap 31. The winding width P1 of the winding 21a is greatly reduced, compared with the winding width P of the conventional one.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a compact and high-performance coil component which is mainly applied to a power supply circuit or an inverter of electronic equipment.

[0002]

2. Description of the Related Art Heretofore, this type of coil component has been constructed by winding a winding around a magnetic core of a closed magnetic circuit. Generally, in order to prevent the inductance value of the winding from decreasing during DC superposition, the magnetic core is prevented. Measures are taken to reduce the magnetic saturation by providing an appropriate gap portion on the magnetic path.

FIG. 8 is a side view showing the basic structure of a conventional toroidal coil component. In this toroidal coil component, a winding wire 21 is radially wound a predetermined number of times around a core 11 with a gap, which is a magnetic core provided with a gap portion 31 having a single width W1, and is wound a predetermined number of times. Therefore, the winding 21 in the core 11 with the gap
The winding width P is obtained.

In the case of this toroidal coil component, as a standard, the core 11 with a gap is made of a soft magnetic metal material having a permeability of μ = 100, an outer diameter φ27 mm × an inner diameter φ14.
The width W1 of the gap part 31 is 6 mm and the height (thickness) is 18 mm, and the winding 21 is wound 12 turns to make the winding width P of the winding 21 in the core 11 with a gap P = 45 mm. The case can be illustrated.

[0005]

In the case of the above-described toroidal coil component, the gap portion is provided on the magnetic path of the core with a gap, which is a magnetic core, so that it is required under the condition that the effective value of the magnetic permeability μ decreases. It is necessary to increase the number of turns of the winding in order to obtain the required inductance value. However, with such a configuration, the DC resistance of the winding increases, and the wire material is likely to deteriorate (copper loss, etc.). In addition, there is a serious problem that it is difficult to realize overall downsizing, loss reduction, resource saving, and energy saving due to an increase in the outer shape of the winding.

Also, in manufacturing, when a winding is wound around a core with a gap in a closed magnetic circuit, it is difficult to wind the winding and the specifications for carrying out mechanical winding are limited. However, there is also a problem that it tends to interfere with the implementation of automated production during manufacturing, and is industrially inappropriate.

Further, in the production of a toroidal type coil component, mechanical winding can be performed by inserting an air-core winding formed by winding a winding in advance from the gap portion of the core with a gap to produce the coil component. Although some technologies have been put to practical use, such a structure requires a sufficient amount of gap to insert the air-core winding in the gap portion of the core with a gap, and therefore has a high inductance. There is a problem that it becomes unsuitable when a value is required.

The present invention has been made to solve the above problems, and its technical problem is to sufficiently prevent the inductance value of the winding from being reduced when the direct current is superposed, and to reduce the size and size of the coil. It is to provide a coil component that can realize loss, resource saving, and energy saving, and that can be easily manufactured by automated manufacturing.

[0009]

According to the present invention, a magnetic core made of a soft magnetic material having a gap portion and a winding wound in advance are formed and then inserted and mounted from the gap portion. In a coil component having an air-core winding, the air-core winding is formed by tightly winding the winding in advance so that the winding width is minimized, and is installed at a position separated from the gap part. A coil component is obtained.

Further, according to the present invention, in the above coil component, a coil component can be obtained in which the gap portion is filled with a filler containing at least a magnetic substance or a non-magnetic substance.

Further, according to the present invention, in any one of the above coil components, the air-core winding is formed by winding the winding on the outside of a winding frame having an inner hole that can be inserted into the magnetic core in advance. A coil component having a framed structure can be obtained.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The coil component of the present invention will be described in detail below with reference to the accompanying drawings with reference to some embodiments.

FIG. 1 is a side view showing the basic structure of a toroidal coil component according to a first embodiment of the present invention. In this toroidal coil component, the winding 21a is preliminarily densely wound a predetermined number of times so that the winding width P1 is minimized with respect to the core 11 with a gap, which is a magnetic core provided with the gap portion 31 having a single width W1. The air-core winding formed by being turned and wound is inserted and mounted from the gap portion 31 so as to be incorporated at the farthest position on the opposite side to the gap portion 31.

In the case of this toroidal coil component, FIG.
As a standard similar to the case shown in, the core with a gap 11
The outer diameter φ27 mm × the inner diameter φ14 mm × the height (thickness) 18 mm, which is made of a soft magnetic metal material having a magnetic permeability μ = 100.
And the width W1 of the gap portion 31 is 6 mm,
Further, if the winding 21a is wound with the same wire as the winding 21 for 12 turns, the winding width P1 (P1 <P) of the winding 21a in the gapped core 11 is 15 mm, which is the same as the conventional winding shown in FIG. As compared with the toroidal coil component, the winding width P1 is compressed to 1/3 of the winding width P.

That is, in the toroidal coil component according to the first embodiment, the winding width P1 of the winding 21a is much smaller than the winding width P of the winding 21 in the conventional case.
In addition to being able to sufficiently prevent the inductance value of the winding from being reduced during DC superposition (the DC superposition characteristic can be greatly improved), it is possible to realize downsizing, low loss, resource saving, and energy saving, and also automated production. It will be easy.

FIG. 2 compares the measured data of the DC superposition characteristic obtained from the relationship of the inductance (μH) with respect to the current (A) in this toroidal coil component with that of the conventional toroidal coil component shown in FIG. It is shown. From FIG. 2, in the case of the toroidal coil component of the first embodiment, the current is 0 to 100 A as compared with the conventional configuration.
It can be seen that the inductance value is increased by about 15 to 20% in the range. This is because in the toroidal coil component of the first embodiment, the inductance value becomes high even though the core 11 with a gap having the same single gap portion 31 as in the conventional configuration is used, Since it has been shown that the number of windings of the winding 21a can be reduced accordingly, such a structure is particularly effective for energy saving due to downsizing of coil parts and reduction of direct current resistance (copper loss etc.). .

FIG. 3 is a side view showing the basic structure of the toroidal coil component according to the second embodiment of the present invention. In the case of this toroidal coil component, the basic structure is almost the same as that of the first embodiment, and the magnetic core provided with the gap portion 31a having a single width W3 (which is assumed to be substantially the same as the width W1). For the core 11a with a gap that becomes
The air core winding formed by winding a by densely turning a predetermined number of times so that the winding width P1 is minimized in advance is formed in the farthest position on the opposite side to the gap portion 31a. In addition to being inserted and mounted from the portion 31a, the magnetic body 4 having a width W2 (W2 <W3) slightly smaller than the width W3 is further provided in the gap portion 31a.
It has a structure in which 0s are backfilled.

Incidentally, a structure in which a non-magnetic material is filled in the gap portion 31a instead of the magnetic material 40 may be used. Generally, a filling material including the magnetic material 40 and the non-magnetic material is used. Any form may be used as long as the material is filled.

The toroidal coil component according to the second embodiment has a structure in which the magnetic body 40 is backfilled in the gap portion 31a, and therefore has a low inductance value in terms of DC superposition characteristics as compared with the first embodiment. It tends to increase when the current is high and decrease when the current is high.
It was confirmed that the effect of having the air-core windings having a high density can be similarly obtained.

FIG. 4 is a side view showing the basic construction of the toroidal coil component according to the third embodiment of the present invention. In the case of this toroidal coil component, the gap portion 31 having a single width W6 (W1 <W6) is used as compared with that of the first embodiment.
b is an amount of deviation ΔW outside the Y axis that passes through the center point O of the inner diameter
The difference is that the core 11b with a gap that is displaced by the amount is used, and the winding width P1 is preliminarily minimized with respect to the core 11b with a gap in the same manner as in the first embodiment. The air-gap winding formed by tightly turning a predetermined number of turns around the gap portion 31b is installed so as to be installed at a position separated from the gap portion 31b on the opposite side.
It is configured by inserting from.

FIG. 5 is a side view shown for explaining how the air core winding is inserted and mounted in the gapped core 11b in the toroidal coil component according to the third embodiment. Here, the air-core portion of the air-core winding formed by densely winding the winding wire 21a is separated from the Y-axis in the vicinity of the gap portion 31b, and the gap portion 31b in one portion of the gap-provided core 11b is raised in the Y-axis direction. Width W from the inner wall surface forming
7 (however, W7 <W6) is inserted with a clearance, and thereafter, the air-core winding is assembled so as to be rotated along one of the portions of the gapped core 11b which is steep in the Y-axis direction. ing.

In the case of the toroidal coil component according to the third embodiment, the gap portion 31b of the core 11b with a gap is formed.
Since it is possible to make the width W6 of the gap larger than the width W1 of the first embodiment or the conventional configuration (that is, W1 <W6), the width of the gap portion is secured to be large in the related art for the reason of characteristics. It is not possible to insert the automatically wound air-core winding from the gap part of the core with a gap to produce a coil component, and the winding work of the winding has to rely on manual winding. Even when it is not obtained, by ensuring the width W6 of the gap portion 31b to be sufficiently large,
It facilitates automated fabrication. Further, under the condition that the number of windings of the winding wire 21a is the same, the automated fabrication becomes easier than the case of the configuration of the first embodiment.

FIG. 6 is a side view showing the basic construction of the toroidal coil component according to the fourth embodiment of the present invention. In the case of this toroidal coil component, the basic configuration is almost the same as that of the first embodiment, and a single width W4 (however, W
4 <W1), the winding core 21c, which is a magnetic core provided with the gap portion 31c, is provided with the winding 21b on the outside of the winding frame 51 having inside the hole which can be inserted into the core 11c with the gap. An air-core winding having a width W5 (provided that W5 <W4) is formed by being wound a predetermined number of times and is wound in the farthest position on the opposite side to the gap 31c. The gap part 31c
It is configured by inserting from.

FIG. 7 is a side view shown for explaining how the air core winding is inserted and mounted in the gapped core 11c in the toroidal coil component according to the fourth embodiment. Here, the air-core portion of the air-core winding having the winding frame structure in which the winding 21b is wound on the outside of the winding frame 51 is the gap portion 31c in one of the gap cores 11c near the gap portion 31c. The figure shows a state in which it is inserted with a clearance from the inner wall surface to be formed, and then the air-core winding of the structure with a winding frame is incorporated so as to be rotated along one side of one of the cores with gap 11c.

In the case of the toroidal coil component according to the fourth embodiment, the gap portion 31c of the core 11c with a gap is formed.
Is smaller than the width W1 in the first embodiment and the conventional configuration (that is, W4 <W1), and the width W5 of the air-core winding having the winding frame structure is set to the gap portion 31c of the gapped core 11c. Is smaller than the width W4 (that is, W5 <W4)
Therefore, under the condition that the number of turns of the winding wire 21b is the same, the size of the winding 21b can be made smaller than that of the configuration of the first embodiment, and the automated fabrication can be easily performed.

In the case of the toroidal type coil component of each of the above-mentioned embodiments, the magnetic core (cores 11 and 11a with a gap,
As the material of 11b, 11c), any soft magnetic material such as dust type, laminated copper plate type, ferrite type, etc. may be applied. Moreover, in the toroidal coil component of each embodiment, a single magnetic core (cores 11 with gap, 11a, 11b, 11) is used.
Although the air core winding including the structure with the winding frame of the present invention can be applied to all coil components using magnetic cores of other forms, it has been described in each embodiment. It is not limited to what is disclosed.

[0027]

As described above, according to the coil component of the present invention, the winding is densely wound in advance on the magnetic core made of the soft magnetic material having the gap so that the winding width is minimized. The air-core winding (including structure with winding frame) formed by turning is inserted from the gap part and installed at a position separated from the gap part, so that the winding It is possible to sufficiently prevent the inductance value from decreasing (the DC superposition characteristic can be greatly improved), and it is the mission of the electronic device to obtain the inductance for the desired current rating, namely miniaturization, low loss, and resource saving. Energy saving can be realized, and further, automated production at the time of production becomes easy, and as a result, it is extremely useful from an industrial and economic standpoint.

[Brief description of drawings]

FIG. 1 is a side view showing a basic configuration of a toroidal coil component according to a first embodiment of the present invention.

FIG. 2 shows measured data of DC superposition characteristics obtained from the relationship between the current and the inductance in the toroidal coil component shown in FIG. 1 in comparison with those of the conventional toroidal coil component shown in FIG.

FIG. 3 is a side view showing a basic configuration of a toroidal coil component according to a second embodiment of the present invention.

FIG. 4 is a side view showing a basic configuration of a toroidal coil component according to a third embodiment of the present invention.

5 is a side view shown for explaining how the air core winding is inserted and mounted in the core with a gap in the toroidal coil component shown in FIG.

FIG. 6 is a side view showing a basic configuration of a toroidal coil component according to a fourth embodiment of the present invention.

7 is a side view shown for explaining how the air-core winding is inserted and mounted in the gapped core in the toroidal coil component shown in FIG.

FIG. 8 is a side view showing a basic configuration of a conventional toroidal coil component.

[Explanation of symbols]

11, 11a, 11b, 11c Gap core 21,21a, 21b winding 31, 31a, 31b Gap part 40 Magnetic 51 reel

Claims (3)

[Claims] 1. A coil component having a magnetic core made of a soft magnetic material provided with a gap portion, and an air-core winding formed by winding a winding in advance and then inserted and mounted from the gap portion. In, the air-core winding is formed by closely winding the winding in advance so that the winding width is minimized,
A coil component incorporated at a position separated from the gap portion. 2. The coil component according to claim 1, wherein the gap portion is filled with a filler containing at least a magnetic substance or a non-magnetic substance. 3. The coil component according to claim 1 or 2, wherein the air-core winding is formed by winding the winding on the outside of a winding frame that has a hole that can be inserted into the magnetic core in advance. A coil component having a framed structure.