JP2005086060A - Low back type transformer and method for manufacturing same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a low back type transformer and a low back type transformer, which can be intended to lower its back and can obtain desired characteristics with excellent insulation. <P>SOLUTION: Flanges 4 having a terminal stand 6 embedded with a pin end 5 are formed at both ends of a hollow drum part 3, respectively, a coil bobbin 1 in which a coil 2 is wound on an outer periphery of the drum part 3 is molded with a resin a, and a middle leg 7 composed of a molded core is inserted into the drum part 3. Thereafter, the transformer is manufactured by attaching molded cores 8, 8' having an opening at the center to an upper surface of the terminal stand 6. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a low profile transformer used in consumer electronic equipment and a low profile transformer.

  In recent years, large-sized electronic devices such as DVD home theaters, liquid crystal TVs, and PDPs are required to be downsized, space-saving, and low-profile. Trans is no exception.

  Normally, a transformer has a core cross-sectional area and a space for winding, which leads to power. However, the core cross-sectional area cannot be secured to reduce the transformer height, and a winding space is also secured. Can not do.

  There are various types of low-profile transformers, for example, Japanese Patent Application No. 2003-40545 previously filed by the applicant of the present application.

  FIG. 12 shows the transformer. The low-profile switching transformer includes a transformer body 24 including a coil bobbin 22 in which a winding 20 and a pin terminal 21 are planted, and a pair of porcelain cores 23, a storage case 25 covering the transformer body 24, The shield case 26 is provided on the inner surface of the storage case 25 and is made of a conductor that covers the transformer main body 24. The resin 26 is injected into the storage case 25 in which the transformer main body 24 is provided.

This transformer is very good as a large capacity type.
Japanese Patent Application No. 2003-40545

  However, since the winding 20 of this transformer is a so-called vertical type, and the porcelain core 23 to be incorporated is incorporated from above and below, the dimensions in the up and down direction, that is, the height direction are inevitably generated, resulting in a low profile. There was a problem that there was a limit.

  The present invention has been proposed in view of the above, and an object of the present invention is to provide a method for manufacturing a low-profile transformer and a low-profile transformer in which a core is arranged in a horizontal direction to achieve a low profile. There is to do.

  In order to achieve the above object, according to claim 1, flanges 4 each having a terminal block 6 in which pin terminals 5 are implanted are formed at both ends of a hollow winding drum portion 3, and the winding drum portion 3 is formed. On the terminal block 6 covered with the resin a, the coil bobbin 1 around which the winding 2 is wound is molded with the resin a, and the middle leg 7 made of a molded core is inserted into the winding body 3. In addition, the cores 8 and 8 'having a center opening formed of a molded core are incorporated on the outer side of the middle foot 7 in the horizontal direction.

  According to claim 2, flanges 4 each having a terminal block 6 in which pin terminals 5 are implanted are formed at both ends of a hollow winding drum portion 3, and windings are wound around the outer periphery of the winding drum portion 3. The resin bob 1 is molded with a coil bobbin 1, a middle leg 7 formed of a molded core inserted into the winding body 3 of the coil bobbin 1, and the middle leg 7 is disposed on the outer side in the horizontal direction. The coil bobbin 1 with the 7 inserted therein is provided with cores 8 and 8 ′ having a center opening formed of a molded core incorporated on the terminal block 6.

  According to a third aspect, in the second aspect, a plurality of the coil bobbins 1 are arranged side by side in the horizontal direction and are integrated by molding resin a, and a middle leg 7 and a core 8 'having an open center are incorporated.

  A fourth aspect of the present invention is characterized in that, in the first, second, or third aspect, the position of the middle leg 7 to be inserted into the winding body part 3 can be adjusted.

  According to the first and second aspects, since the cores 8 and 8 ′ having the center opened on the outer side in the horizontal direction of the middle foot 7 are arranged, the dimension in the height direction is not increased. Can be achieved.

  Further, since the coil bobbin 1 having the winding 2 is molded with the resin a, the insulation is good, the barrier tape can be eliminated, the winding space can be utilized 100%, and the coupling of the winding is also good. .

  According to the third aspect, since the winding 2 is divided into a plurality, the winding space can be secured and the windings 2 are arranged in parallel in the horizontal direction, so that the dimension in the height direction can be reduced and the height can be further reduced. Can be achieved.

  According to the fourth aspect, since the position of the middle leg 7 to be inserted into the winding body part 3 can be adjusted, the characteristics can be finely adjusted.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[Embodiment 1]
FIGS. 1-6 is explanatory drawing which shows the manufacturing process of the low profile transformer concerning 1st Example of this invention.

  In FIG. 1, reference numeral 1 denotes a coil bobbin made of a molded product of an insulating resin. The coil bobbin 1 has a hollow winding body 3 around which windings 2 are wound on the outer periphery and both ends of the winding body 3. The flange 4 is formed and provided with a terminal block 6 projecting in the bobbin axial direction on the lower outer side of the flange 4 and having several enemy pin terminals 5 implanted in the lower part. An elongated middle leg 7 having a rectangular cross section is disposed in the hollow portion 3 a of the winding drum portion 3.

  The middle leg 7 is inserted into the hollow part of the winding drum part 3, and this middle leg 7 is formed of a molded core of ferrite, for example. The hollow portion 3a of the winding drum portion 3 is formed in a horizontally long shape in order to reduce the height in the illustrated state. The middle leg 7 has a cross-sectional shape corresponding to the window shape of the hollow portion 3a so that it can be inserted into the hollow portion 3a of the winding drum portion 3. If the cross-sectional area of the middle leg 7 is arbitrarily adjusted within a range that can be accommodated in the winding drum section 3, the power of the transformer can be appropriately changed.

  In assembling, first, the winding 2 is wound around the winding body 3 of the coil bobbin 1, and the lead wire (not shown) is formed in a lead groove (not shown) formed in the terminal block 6 of the coil bobbin 1. It is entangled with the root of a predetermined pin terminal 5 via a soldering connection.

  Next, as shown in FIG. 2, the surface of the coil bobbin 1 around which the coil 2 is wound is molded with an insulating resin a to obtain a molded body 1A. This mold may use a known appropriate resin molding technique.

  In this way, by using the molded body 1A, insulation can be ensured, and a barrier tape for taking a creepage distance required in the conventional safety standard has been provided on the winding body part 3, but this can be deleted. And 100% of the winding space can be utilized. Further, since the winding 2 is well coupled, high efficiency can be achieved.

  Next, as shown in FIG. 3, the middle foot 7 is inserted into the hollow portion 3 a of the winding drum portion 3. When the middle leg 7 is inserted into the winding drum part 3, it is formed in a length dimension that fits within the winding drum part 3, and does not protrude outside.

  Next, as shown in FIGS. 4 and 5, a core 8 made of a molded core made of the same material as that of the middle foot 7 and having a substantially square-shaped center opening is placed on the upper surface of the terminal block 6 covered with the resin a. To do. The core 8 is disposed outside the middle foot 7 in the horizontal direction, and the middle foot 7 and the core 8 constitute a closed magnetic circuit.

  In assembling, the coil bobbin 1 also functions as a positioning member, and a middle leg 7 having a desired shape and size is inserted into the winding body 3 of the coil bobbin 1 having a predetermined shape and size, and the center is opened on the terminal block 6. When the core 8 is attached, the middle leg 7, the square-shaped core 8, and the like can be arranged at appropriate positions with each other, and can be integrated via the coil bobbin 1.

  In this case, as shown in the assembly perspective view of FIG. 5, if the upper part of the assembly A is in a shape that fits in the square-shaped core 8, the height can be reduced.

  In addition, the end surface of the middle leg 7 inserted in the winding drum part 3 is normally disposed opposite to the center of the side surface inner surface of the core 8 having an open center.

  However, as shown in FIG. 6, for example, an insulating spacer 9 is arranged in the lower portion of the hollow portion 3 a of the winding drum portion 3, and a middle leg 7 is incorporated on the spacer 9. The magnetic characteristics can be finely adjusted by adjusting the position. Further, as another means, the position of the middle foot 7 can be adjusted by raising the bottom of the hollow portion 3a into which the middle foot 7 of the coil bobbin 1 is inserted in advance. In this case, a spacer member is unnecessary. It is preferable.

  Further, a plurality of coil bobbins 1 having different sizes are prepared in advance, and a desired coil bobbin 1 including a winding body portion 3 having a hollow portion 3a having a sufficient size with respect to the shape of the middle leg 7 is selected, It can also be performed by adjusting the insertion position of the winding drum part 3 into the hollow part 3a and inserting and fixing the middle leg 7.

[Embodiment 2]
7 to 11 show the assembly process of the second embodiment of the present invention.

  The second embodiment is an application example of the first embodiment. In the above-described embodiment, the winding 2 is a so-called vertical type and has only one. In general, the winding must be wound a predetermined number of times to obtain the desired characteristics. For this reason, the winding 2 is enlarged and a height dimension is generated, which hinders miniaturization and low profile. In this application example, the winding space is secured by dividing the winding 2 into two, and a pair of coil bobbins 1 each having the winding 2 are arranged side by side in the horizontal direction and integrated by molding, 7, and a core 8 ′ having a substantially square-shaped center opening made of a molded core formed in a shape corresponding to the coil bobbin 1 is arranged on the outer side in the horizontal direction of each middle foot 7. Yes.

  That is, in FIG. 7, the coil bobbins 1 each having the winding 2 are juxtaposed in the horizontal direction. The primary and secondary windings of each winding 2 are connected.

  These coil bobbins 1 are first molded with a resin a as shown in FIG. 8 to obtain a molded body 1A ′.

  Next, as shown in FIG. 9, the middle foot 7 is inserted into the hollow portion 3 a of each winding drum portion 3 covered with the resin a.

  Next, as shown in FIGS. 10 and 11, the core 8 'may be provided on the terminal block 6 covered with the resin a.

  If the winding 2 is divided into two as in this application example, the winding space can be secured and the profile can be further reduced, and each winding wound around the outer side of each middle foot 7 can be achieved. Since 2 is surrounded by the core 8 ', the leakage is good. Furthermore, when the installation space for incorporating the transformer can only secure a long and narrow space, it is preferable to use the transformer of this application example.

  Other configurations are the same as those in the above-described embodiment.

The perspective view of a coil bobbin concerning the 1st example of the present invention, a middle leg incorporated in it, etc. is shown. Explanatory drawing of the assembly process of an Example same as the above is shown. The assembly process explanatory drawing of the next process same as the above is shown. Explanatory drawing of the further next assembly process same as the above is shown. The assembly perspective view of a completed state is shown. The example of arrangement | positioning of the middle leg position in a winding drum part is shown. A perspective view of a coil bobbin concerning the 2nd example of the present invention, a middle leg incorporated in it, etc. is shown. Explanatory drawing of the assembly process of an Example same as the above is shown. The assembly process explanatory drawing of the next process same as the above is shown. The assembly process explanatory drawing of the next process same as the above is shown. The assembly perspective view of a completed state is shown. The structure explanatory drawing of a prior art example is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil bobbin 1A, 1A 'Mold body 2 Winding 3 Winding drum part 3a Hollow part 4 Flange 5 Pin terminal 6 Terminal block 7 Middle leg 8, 8' Core 9 Spacer

Claims (4)

A flange (4) having a terminal block (6) in which pin terminals (5) are implanted at both ends of a hollow winding body (3) is formed, and wound around the outer periphery of the winding body (3). The coil bobbin (1) around which the wire (2) is wound is molded with the resin (a), the middle leg (7) made of a molded core is inserted into the winding body (3), and the resin (a) A low profile transformer comprising a core (8, 8 ') formed of a molded core on the coated terminal block (6) and having a center opening formed on the outer side in the horizontal direction of the middle foot (7). Manufacturing method. A flange (4) having terminal blocks (6) in which pin terminals (5) are implanted at both ends of a hollow winding body (3) is formed, and wound around the outer periphery of the winding body (3). A coil bobbin (1) wound with a wire and molded with resin (a);
A middle leg (7) comprising a molded core inserted into the winding body (3) of the coil bobbin (1);
A core having an opening in the center made of a molded core that is disposed on the outer side in the horizontal direction of the middle leg (7) and is incorporated on the terminal block (6) of the coil bobbin (1) into which the middle leg (7) is inserted ( 8, 8 ′) and a low profile transformer. 3. The coil bobbin (1) according to claim 2, wherein a plurality of the coil bobbins (1) are juxtaposed in a horizontal direction and molded by resin (a), and a middle leg (7) and a core (8 ') having an open center are incorporated. Low profile transformer characterized by The low profile transformer according to claim 1, 2, or 3, wherein the position of the middle leg (7) to be inserted into the winding body (3) is adjustable.

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