JP2003264110A - Spiral coil and transformer - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a spiral coil and a transformer using this coil which can reduce the number of components and assembly man-hours but can improve the reliability while reducing the costs. <P>SOLUTION: The spiral coil 1 is made by stamping a metal sheet. The outer ends of the two coils 1a, 1b are connected by a link 1c which is made at the same time when stamping. The link 1c is folded so that the two coils 1a, 1B face or overlap each other to direct the magnetic flux of the two coils 1a, 1b in the same direction. The transformer uses a spiral coil as the first coil and a second coil is disposed between the two coils 1a, 1b. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a spiral coil used for an inductor or a transformer and a transformer using the spiral coil.

[0002]

2. Description of the Related Art In the spiral coil, the actual construction of Shokai 6
As described in Japanese Patent Laid-Open No. 0-37210, a terminal plate provided separately from the coil is prepared in order to draw the coil inner end portion as a terminal in the radial direction of the coil, and one end of the terminal plate is connected to the coil inner end and the terminal is connected. An insulating material is interposed at a position where the plate intersects with the coil, and the other end of the terminal plate is drawn out of the coil.

Japanese Unexamined Patent Publication (Kokai) No. 4-63408 discloses a spiral coil in which an inner end of a spiral coil is horizontally drawn outward, and a portion where the drawn portion intersects the coil is curved so as not to come into contact with the coil. ing.

In Japanese Utility Model Laid-Open No. 60-37210, two spiral coils are superposed with an insulating material interposed therebetween, and the inner ends of the two spiral coils are connected through an opening provided in the insulating material. It is disclosed.

[0005]

SUMMARY OF THE INVENTION The spiral coil described in each of the above-mentioned publications has a double coil structure.
It is necessary to prepare two spiral coils configured separately, and it is inevitable that the number of parts will increase. In addition, a connecting process for connecting the inner ends or the outer ends of the two separate spiral coils is indispensable, and the number of man-hours increases. Therefore, the number of parts increases and the cost increases. There is a point. In addition, there is a problem that the electrical resistance increases at the connection portion between the terminal plate and the inner end of the coil, and the reliability decreases due to variations in the electrical resistance.

In view of the above situation, it is an object of the present invention to provide a spiral coil and a transformer using the spiral coil, which can reduce the number of parts and man-hours, reduce costs associated therewith, and improve reliability.

[0007]

A spiral coil according to a first aspect of the present invention is a spiral coil produced by punching a metal plate, wherein each of the spiral-shaped two coil main bodies has an outer peripheral side end formed of the metal plate. Two coil bodies are formed by being connected to each other by a series of connecting portions formed by punching, and the connecting portions are bent so that the magnetic fluxes generated by the two coil bodies are in the same direction. It is characterized by having a different structure.

In this spiral coil, two coil bodies are punched out from one metal plate so that their outer peripheral sides are connected to each other, and the connecting portions are faced by the two coil bodies or made of an insulating material. It can be manufactured by bending so as to overlap with each other. Therefore, it is not necessary to separately prepare a connecting member for the two coil bodies or to perform a connecting step, the number of parts and man-hours can be reduced, and cost can be reduced. In addition, the problem of a decrease in electrical resistance at the connection between the two coil bodies is eliminated, and reliability is improved.

A spiral coil according to a second aspect of the invention is characterized in that the inner ends of the two coil bodies are folded outward to form a terminal.

As described above, the inner end of each coil body is also folded outward to form a terminal, so that a separate member for pulling out the inner end of the coil body is not required.

The transformer of claim 3 is the transformer of claim 1 or 2.
The spiral coil described in 1 above is used as the first coil, and
It is characterized in that individual coil main bodies are opposed to each other with a space and a second coil is arranged between these coil main bodies.

With this configuration, it is possible to realize a highly reliable transformer that secures the number of turns of the first coil and has a small number of connecting portions.

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1A is a perspective view showing an embodiment of a spiral coil according to the present invention, FIG.
FIG. 3C is a plan view and a side view showing a state before bending the connecting portion between the coil bodies. The coil 1 has two coil bodies 1a and 1b wound in a spiral shape, that is, with a number of turns exceeding one turn. These coil bodies 1a and 1b are manufactured by punching a metal plate.

In this spiral coil, as shown in FIG. 1B, a metal plate is punched out to form two coil bodies 1a,
At the same time as punching out 1b, both connecting portions 1c are punched out integrally with these coil bodies 1a, 1b. Then, the connecting portion 1c is folded substantially at a right angle along the lines 9 and 10 in FIG.
As shown in (A), a spiral coil in which two coil bodies 1a and 1b face each other is obtained.

In the present embodiment, each coil body 1
The inner ends of a and 1b are, as shown in FIG. 1B, inwardly facing portions 1d and 1e (two-dot chain line) formed on the thin plate so as to traverse the inner space of the spiral in the punched state. Indicated by). The external connection terminal 1 shown by the solid line is formed by bending the inward portion outward so as to be folded back.
d, 1e.

In the present embodiment, as shown in FIG. 1C, a gap g is provided between the terminals 1d, 1e and the coil body portions 1a, 1b in order to insulate them from each other.
Each terminal 1d, 1e has a hole 1f for inserting a screw or the like for connecting to another device or wiring. This spiral coil is used as an inductor or a transformer by combining cores as necessary.

Thus, the two coil bodies 1a and 1b are
Since they are connected to each other by the bent connecting portion 1c, it is not necessary to separately prepare a connecting plate dedicated for connection to form a double coil, the number of parts and man-hours can be reduced, and cost can be reduced. Further, the problem of reduction in electric resistance at the connecting portion 1c between the coil bodies 1a and 1b is eliminated, and the reliability is improved.

When carrying out the present invention, the external connection terminal 1
Although d and 1e may be formed separately and connected to the inner ends of the coil bodies 1a and 1b by welding, soldering or a fixture, these terminals 1d and 1e may be connected as in the present embodiment.
By integrally forming e in the outwardly folded shape, the connecting portions of the terminals 1d and 1e are also eliminated, so that there is no problem of reduction in electric resistance at the connecting portions of these terminals 1d and 1e, and reliability is improved. Further improve.

In the present embodiment, the terminal 1
In order to secure the length of d, 1e, the coil bodies 1a, 1b
Since the portion that forms is formed from the portions 1g and 1h that bulge outward from the arc line, the lengths of the terminals 1d and 1e can be easily ensured. Reference numerals 1i and 1j are locking pieces used when configuring a transformer described later, and are not necessarily required.

2A to 2C are side views showing another embodiment of the spiral coil of the present invention.
In each of these spiral coils, an insulating material 6 is sandwiched and fixed between the two coil bodies 1a and 1b to insulate the two coil bodies 1a and 1b. According to the present embodiment, the connecting portion 1c may be bent at one place, and since it is not necessary to provide the gap g for insulation between the coil bodies 1a and 1b, there is an advantage that the structure can be made thin. is there.

In the embodiment shown in FIG. 2B, the terminal 1 is used.
The d and 1e are not formed parallel to the coil bodies 1a and 1b, but are formed at an inclined angle. Terminal 1a
In addition to this, various shapes can be formed.

In the embodiment shown in FIG. 2C, the insulating material 6a is also provided between the terminals 1d and 1e and the coil bodies 1a and 1b.
6b is interposed. According to this embodiment,
The spiral coil can be made even thinner.

The shape of the coil body in the present invention is not limited to a perfect circle, and various shapes such as an ellipse, an ellipse, and a polygon can be adopted.

FIG. 3 (A) is an exploded perspective view showing an embodiment of the transformer according to the present invention except for the portion of the spiral coil 1, and FIG. 3 (B) is a combined structure of the spiral coil 1 and a case. It is a side view explaining. 4A and 4B are an overall view and a cross-sectional view of the transformer according to the present embodiment, respectively. In FIGS. 3 and 4, reference numeral 1 is the first coil formed of the spiral coil shown in FIG. 1, and is used as the low voltage side coil. The second coil 2 is used as a high-voltage coil having many turns. 3 is a bobbin around which the second coil 2 is wound,
4,5 are cores.

As shown in FIG. 3 (A), the bobbin 3 has two cylindrical flanges 3b, which are spaced apart from each other and are provided on the cylindrical winding barrel 3a.
Further, as shown in FIG. 4 (B), it has a winding separation piece 3c formed in the circumferential direction between the collar portions 3b, 3b. The winding separation piece 3c is provided for preventing winding disorder and is provided on both sides of the winding except the lead-out portion and the opposite side.

The second coil 2 is composed of two layers of flat coils 2a and 2b spirally wound around the winding drum portion 3a of the bobbin 3, and is separated by the winding separating piece 3c from the winding drum portion 3a of the bobbin 3. Then, by winding one wire rod 2, the planar coils 2a, 2
b has a structure in which it is continuously stacked in the axial direction on the inner peripheral side, and it is possible to prevent winding collapse. The coil terminals 2c, 2d for pulling out the plane coils 2a, 2b are pulled out from the outer peripheral side of the plane coils 2a, 2b. Figure 4
In (A), 2e and 2f are the coil terminals 2c and 2f.
It is a wire connected to d.

The cores 4 and 5 of this example are E-shaped cores, and main magnetic legs 4a and 5a, side magnetic legs 4b and 5b, main magnetic legs 4a and 5a and side magnetic legs 4b and 5b, respectively. It has bridge portions 4c and 5c which connect between them. These cores 4 and 5 are obtained by inserting the main magnetic legs 4a and 5a into the cylindrical winding drum portion 3a,
The side magnetic legs 4b, 5b are arranged on the outer peripheral side of the collar portion 3b so that the bridging portions 4c, 5c and the side magnetic legs 4b, 5b surround at least a part of the second coil 2 and the first coil 1. To form a closed magnetic circuit.

This transformer has a first case 7 and a second case 8 as insulating cases. The first case 7 and the second case 8 are plate-like portions 7b and 8b provided with magnetic leg insertion holes 7a and 8a for inserting the main magnetic legs 4a and 5a of the cores 4 and 5, respectively, and the plate-like portions. Side walls 7c and 8c are formed which extend substantially vertically from the outer peripheral portions of the portions 7b and 8b. The side walls 7c and 8c of the first case 7 and the second case 8 have a tubular structure that overlaps each other in the radial direction of the coil 2 and have cutouts 7d and 8d for drawing out the winding wire. Have.

In the transformer having the insulating case, the bobbin 3 around which the second coil 2 is wound is covered with the first case 7 and the second case 8, and the terminals 2c and 2d are provided with the cutout portion 7d. Pull out from 8d.

The cores 4 and 5 are the main magnetic legs 4a and 5a.
Is inserted into the winding body portion 3a and into the magnetic leg insertion holes 7a and 8a of the first coil 1 and the first case 7 and the second case 8, and the side magnetic legs 4b and 5b are side wall portions 7c and 8c. Placed outside of.

When the present invention is carried out, the first coil 1 has the plate-like portions 7b of the first case 7 and the second case 8,
Although it may be adhered to 8b, in the present embodiment, the following locking structure is used to prevent the first coil 1 from rising from the first cases 7 and 8.

That is, the outer peripheries of the coil bodies 1a, 1b of the first coil 1 are formed in a circular shape, and a pair of terminals 1d, 1e are provided on one end side of the first coil 1 so as to project, and the other ends thereof project substantially in the radial direction. Locking pieces 1i, 1j are provided. Also,
The first coil 1 includes a case 7 between the coil bodies 1a and 1b,
There is a space so that 8 are arranged. Then, the first coil bodies 1a and 1b are arranged outside the plate-shaped portions 7b and 8b of the first case 7 and the second case 8.

On the other hand, the outer surface of the plate-shaped portions 7b and 8b opposite to the bobbin 3 is used as the mounting surface of the first coil 1, and the first coil bodies 1a and 1b are surrounded by the mounting surface.
Fitting walls 7e and 8e are provided for fitting. In addition, the fitting walls 7e and 8e of the cases 7 and 8 are cut out on the terminals 1d and 1e side of the first coil 1 and on the opposite side thereof, and are extended to the cutout portions in the radial direction. Departure part 7f, 7g
And 8f, 8g are provided, the first locking portions 7h, 8h are provided on one of the extending portions 7f, 8f, and the other extending portions 7g, 8g are provided.
Second locking portions 7i and 8i are provided on the respective.

In order to mount the spiral coil 1, no wall is provided on the side of the extending portions 7f, 8f on the first coil introducing side of the cases 7, 8 opposite to the engaging portions 7h, 8h, and the spiral coil 1 is terminated in a plate shape. , The mating walls 7e and 8e on the side continuous with the terminal end
The slanted side 7j for slide where the height of the wall gradually increases,
8j.

The first coil 1 is attached to the cases 7 and 8 by utilizing the elasticity of the spiral coil 1 from the side where the locking pieces 1i and 1j of the first coil 1 are formed,
Slide the coil body 1a while riding on 8j,
1b is fitted into the fitting walls 7e and 8e, and then the first coil 1 is rotated to lock the locking pieces 1i and 1j of the first coil 1.
Are engaged with the engaging portions 7i and 8i of the cases 7 and 8, respectively, and the bulging portions 1g and 1h of the coil bodies 1a and 1b are made to slip into the first engaging portions 7h and 8h, respectively. The coil 1 is prevented from rising from the cases 7 and 8. The coil 1 is fixed to the cases 7 and 8 with a tape or an adhesive (not shown). Reference numeral 11 is an exterior metal fitting for connecting the cores 7 and 8.

In the transformer of this embodiment, since the spiral coil is used as the first coil 1, the above-described effects of reducing the number of parts and man-hours, reducing costs, and improving reliability can be obtained. In addition, the thickness of the second coil 2 becomes the thickness of the two layers of the flat coil 2a, 2b wound in a spiral shape, which is the thickness of the wire rod of the lead-out portion from the inner end of the spiral coil as in the conventional case. In addition, the total thickness of the plane coil does not double, the space factor is improved, and the thickness is prevented from increasing even when two layers of plane coils are stacked. Further, although the first coil 1 has a large current value, since it is configured by using a metal flat plate formed by punching a metal plate, a combination of the second coil 2 and the first coil 1 reduces the thickness. The transformer can be constructed, and since the first coil 1 has a spiral shape and two coils are combined, the number of turns can be increased.

Further, the first coil 1 is attached to the locking portions 7h and 8h.
And by fixing to the insulating cases 7 and 8 by a structure for preventing floating by 7i and 8i, a space is secured between the first coil 1 and the cores 4 and 5, and insulation is achieved without using a special insulating material. Therefore, the number of parts can be reduced.

In this embodiment, the first coil 1 is used as the low-voltage side coil and the second coil 2 is used as the high-voltage side coil constituted by windings. However, the second coil is also punched out of a metal plate. A coil may be used as the low voltage side coil, and the first coil 1 may be used as the high voltage side coil.

[0039]

According to the first aspect of the present invention, since the two coil bodies are formed by being connected to each other by the connecting portion integrated with the coil body, it is necessary to separately prepare a connecting member and connect the coil body to the coil. , The number of parts and man-hours are reduced,
Cost reduction can be achieved. Further, since a connecting plate for connecting the coil bodies is not necessary, the problem of a decrease in electric resistance at the connecting portion is eliminated and reliability is improved.

According to the second aspect, since the inner end of each coil body is also outwardly folded back to form a terminal, a separate member for pulling out the inner end side of the coil body is not required. The effect of is promoted.

According to the third aspect, since the spiral coil is the first coil facing each other with a space and the second coil is arranged between the coil bodies, the turn of the first coil is made. It is possible to realize a highly reliable transformer with a large number of connected parts.

[Brief description of drawings]

FIG. 1A is a perspective view showing an embodiment of a spiral coil according to the present invention, and FIGS. 1B and 1C are plan views showing a state before a coil body connecting portion is bent, respectively.
It is a side view.

2 (A) to 2 (C) are side views showing another embodiment of the spiral coil according to the present invention.

FIG. 3A is an exploded perspective view showing an embodiment of a transformer according to the present invention, excluding a spiral coil, and FIG. 3B is a side view for explaining the attachment of the first coil to a case.

4A is a perspective view showing a state after assembly of the transformer of FIG. 3, and FIG. 4B is a sectional view thereof.

[Explanation of symbols]

1: spiral coil, 1a, 1b: coil body, 1
c: connection part, 1d, 1e: terminal, 1g, 1h: bulge part,
1i, 1j: locking piece, 2: second coil, 3: bobbin,
4, 5: core, 6, 6a, 6b: insulating material, 7, 8: case, 9, 10: bent portion, 11: exterior fitting

[Procedure amendment]

[Submission date] March 12, 2002 (2002.3.1)
2)

[Procedure Amendment 1]

[Document name to be corrected] Drawing

[Correction target item name] All drawings

[Correction method] Change

[Correction content]

[Figure 1]

[Fig. 2]

[Figure 4]

[Figure 3]

Claims (3)

[Claims] 1. A spiral coil manufactured by stamping a metal plate, wherein each outer peripheral end of two spiral coil bodies is connected to each other by a connecting portion formed in series by stamping the metal plate. A spiral coil having a structure in which two coil bodies are faced or overlapped with each other so that the connecting portions are bent and the magnetic fluxes generated by the two coil bodies are in the same direction. 2. The spiral coil according to claim 1, wherein each of the inner ends of the two coil bodies is bent outward to form a terminal. 3. The spiral coil according to claim 1 or 2 is used as a first coil, the two coil bodies are opposed to each other with a gap, and a second coil is arranged between these coil bodies. A transformer characterized by that.