JP2005093493A - Low profile transformer and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a low profile transformer which is reduced in height by dividing a winding into two sets of sub-winding and to provide its manufacturing method. <P>SOLUTION: Coil bobbins 1 equipped with sets of winding 7 wound on the peripheral surfaces of their hollow winding drums 2 are arranged in a horizontal direction and sealed up with resin (a) so as to be integrated. A lower core 8 is composed of a plate-like long and thin main body 8a, middle legs 8b formed thereon, and outer legs 8c provided upright at the ends of the main body 8a. The sealed coil bobbins 1 are arranged on the lower core 8 confronting it and inserting the middle legs 8b into the hollows of the winding drums 2 for assembly, and an upper core 9 is put on the top of the assembly, and a gap between the assembly and the upper core 9 is filled up with resin for the formation of a low transformer of integral structure. <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, various electronic devices have been required to save space, and accordingly, there has been a trend toward downsizing, low profile, and the like.

  Low-profile devices such as DVD home theaters and liquid crystal TVs are expected to become the mainstream of demand in the future. As a result, the power supply transformer is naturally required to have a low profile.

  Usually, a transformer has a core cross-sectional area and a winding space that leads to power. However, the core cross-sectional area cannot be secured to reduce the transformer height, and a winding space is also secured. become unable.

  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. 5 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, in this transformer, the winding 20 is a so-called vertical type wound from below to above, and in order to obtain desired characteristics, the winding must be wound a predetermined number of times. In this case, the winding has a problem that the shape in the height direction and the horizontal direction becomes large, which hinders miniaturization and low profile.

  Further, in this transformer, since the porcelain core 23 is built in from above and below, the dimensions in the height direction are inevitably produced, and there is a limit to the reduction in height.

  The present invention has been proposed in view of the above, and the object thereof is to divide the winding into two parts and reduce the height of the mold type low-profile transformer and low-profile transformer. Is to provide.

  2. A plurality of coil bobbins 1 each having a winding 7 wound around an outer periphery of a hollow winding body 2 are arranged in parallel in the horizontal direction, and the coil bobbins 1 are molded and integrated with a resin a. The molded coil bobbin 1 is opposed to a lower core 8 in which a plurality of middle legs 8b are formed on a plate-like main body 8a, and outer legs 8c are erected on the ends of the main body 8a. The middle leg 8b is inserted into the winding drum portion 2 and incorporated, and the plate-like upper core 9 is covered on the assembly, thereby achieving the above object.

  According to a second aspect of the present invention, in the first aspect, a lower flange 4 and an upper flange 5 are formed at each end portion of the winding body portion 2 of the coil bobbin 1, and a plurality of lower flanges 4 are formed at both ends of the lower surface of the lower flange 4. The terminal portions 4a in which the pin terminals 6 are implanted are respectively formed, the main body 8a of the lower core 8 is positioned between the terminal portions 4a, and the upper core 9 is disposed at the upper end of the outer leg 8b of the lower core 8. Is configured to be joined.

  According to a third aspect of the present invention, a low-profile transformer includes a plurality of windings 7 wound around the outer periphery of the hollow winding body 2 and arranged in parallel in the horizontal direction, and molded and integrated with a resin a. A coil bobbin 1, a lower core 8 having middle legs 8 b inserted into the winding body 2 of the molded coil bobbin 1, and outer legs 8 c erected at the ends, respectively, The side core 8 and the coil bobbin 1 are arranged to face each other, and a plate-like upper core 9 that covers the coil bobbin 1 is provided.

  According to a fourth aspect of the present invention, there is provided a low profile transformer, and in the third aspect of the present invention, a lower flange 4 and an upper flange 5 are respectively formed at each end of the winding body portion 2 of the coil bobbin 1. Terminal portions 4a in which a plurality of pin terminals 6 are implanted are formed at both ends of the lower surface, and the main body 8a of the lower core 8 is located between the terminal portions 4a, and the outer legs 8c of the lower core 8 are The upper core 9 is joined to the upper end.

  According to the first to fourth aspects, since the winding 7 is divided into two and arranged in parallel in the horizontal direction, the height can be reduced.

  Further, by dividing the winding 7 into two, a winding space can be secured and the width of the outer core can be reduced to ½. Compared to one coil, the floor area can be reduced.

  Further, since the coil bobbin 1 having the winding 2 is molded with the resin a, the insulation can be surely performed, and the barrier tape wound around the end of the winding body 2 of the coil bobbin 1 can be eliminated by filling the resin. 100% of space can be used.

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

  1 to 4 are explanatory views showing a manufacturing process of a low profile transformer according to one embodiment of the present 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 cylindrical winding body 2, and each end of the winding body 2 has a lower flange 4, Upper flanges 5 are respectively formed. In FIG. 1, reference numeral 3 denotes a hollow portion of the winding drum portion 2.

  The lower flange 4 is formed in a substantially rectangular plate shape, thick terminal portions 4a are formed at the lower portions of both ends, and an appropriate number of pin terminals 6 are implanted below the respective terminal portions 4a.

  The upper flange 5 is formed in a disk shape corresponding to the winding 7 (shown by phantom lines) wound around the outer periphery of the winding drum section 2.

  In the present invention, as shown in FIG. 1, a plurality of coil bobbins 1 are arranged adjacent to each other in the horizontal direction, a plurality of winding body portions 2 are formed in the horizontal direction, and a winding space is secured.

  Reference numeral 8 denotes a lower core made of a molded core, which is formed of a material such as ferrite. The lower core 8 is formed in a shape substantially corresponding to the shape of the coil bobbin 1 and has a plate-like main body 8a, and a columnar middle leg that can be inserted into each winding body 2 on the upper surface of the main body 8a. A pair of 8b is formed at a predetermined interval, and outer legs 8c bent upward are formed at each end in the length direction of the main body 8a.

The length l ₁ between the outer leg 8c of the upper surface of the main body 8a is formed equal to the length dimension l ₁ of the two coil bobbin 1 arranged side by side, the width dimension l ₂ of the main body 8a is lower flange both ends of the coil bobbin 1 Are formed to be equal to the dimension l ₂ between the respective terminal portions 4a.

Reference numeral 9 denotes a plate-shaped molded core, which is an upper core made of the same material as the lower core 8. The upper core 9 has an elongated rectangular shape, and is provided so as to cover the outer legs 8c at both ends of the lower core. In other words, the length l ₃ of the upper core 9 is formed equal with the lower surface side of the length l ₃ of the main body 8a of the lower core 8. The coil bobbin 1, the lower core 8, and the upper core 9 are not limited to the illustrated example, and may be square.

  Next, an assembly example will be described.

  Windings 7 are wound around the winding body 2 of each coil bobbin 1. The primary and secondary windings of these windings 2 are connected and function as a normal one winding of the transformer.

  As is well known, the lead wire (not shown) of each winding 7 is tangled to the base of a predetermined pin terminal 6 via a lead groove (not shown) formed in the terminal portion 4a, and is connected by soldering. Is done.

  Next, as shown in FIG. 2, the winding 2 is wound, and the coil bobbins 1 arranged side by side are molded and integrated with an insulating resin a to obtain a molded body 1A. This can be done by a known appropriate molding technique.

  By molding in this way, the insulation tape is improved and the barrier tape for providing the creeping distance required in the conventional safety standard has been provided in the winding drum part 2, but it can be removed and the winding 100% of space can be used. Further, since the winding 7 is well coupled, high efficiency can be achieved.

  Next, as shown in FIG. 3, the coil bobbin 1 made of the molded body 1A is disposed on the lower core 8 so as to be placed inside the hollow part 3 of the winding body 2 of the coil bobbin 1 made of the molded body 1A. The foot 8b is inserted.

  In this case, the upper surface of the upper flange 5 and the upper end of the outer leg 8b are substantially flush.

  Next, if the upper core 9 is disposed on the upper core 9 and the upper core 9 and the middle leg 8b are joined and integrated, the low-profile transformer 10 can be assembled.

  FIG. 4 shows the assembled state.

  In this transformer, the winding space can be ensured by dividing the winding 7 into two parts, and each winding 7 can be reduced in size as compared with the transformer of one winding type, so that the floor area can be reduced.

  Also, the width of the outer core can be reduced to ½.

  This transformer can be used for a power source part such as a DVD home theater, a liquid crystal TV, a PDP, and a mobile computer SWAD.

The disassembled perspective view of one Example of this invention is shown. Explanatory drawing of one assembly process of an Example same as the above is shown. The perspective view of the assembly process of an Example same as the above is shown. The perspective view of the assembly state of an Example same as the above is also shown. The longitudinal cross-sectional view of a prior art example is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil bobbin 1A Mold body 2 Winding drum part 3 Hollow part 4 Lower flange 4a Terminal part 5 Upper flange 6 Pin terminal 7 Winding 8 Lower core 8a Body 8b Middle leg 8c Outer leg 9 Upper core 10 Low profile transformer a Resin

Claims (4)

A plurality of coil bobbins (1) each having a winding (7) wound around the outer periphery of a hollow winding body (2) are juxtaposed in a horizontal direction, and these coil bobbins (1) are molded with resin (a). The molded coil bobbin (1) has a plurality of middle legs (8b) formed on a plate-like main body (8a) and outer legs (8c) at the end of the main body (8a). ) Are arranged opposite to each other on the standing lower core (8), and the middle foot (8b) is inserted into the winding body (2) and assembled, and a plate-like upper core is mounted on the assembly. (9) A method for producing a low-profile transformer characterized by covering. 2. The lower flange (4) according to claim 1, wherein a lower flange (4) and an upper flange (5) are formed at each end of the winding body (2) of the coil bobbin (1), and the lower surface of the lower flange (4). Terminal portions (4a) in which a plurality of pin terminals (6) are implanted are formed at both ends, and the main body (8a) of the lower core (8) is located between the terminal portions (4a), and A method for producing a low profile transformer, characterized in that the upper core (9) is joined to the upper end of the outer leg (8b) of the lower core (8). A plurality of coil bobbins (1) in which the winding (7) is wound around the outer periphery of the hollow winding body (2) and arranged in parallel in the horizontal direction, and molded and integrated with the resin (a);
A lower core (having a middle leg (8b) to be inserted into the winding body (2) of the molded coil bobbin (1) and an outer leg (8c) standing on the end ( 8) and
A low-profile transformer comprising the lower core (8) and a plate-like upper core (9) that is disposed opposite to the coil bobbin (1) and is placed on the coil bobbin (1). The lower flange (4) according to claim 3, wherein a lower flange (4) and an upper flange (5) are formed at each end of the winding body (2) of the coil bobbin (1), and the lower surface of the lower flange (4). Terminal portions (4a) in which a plurality of pin terminals (6) are implanted are formed at both ends, and the main body (8a) of the lower core (8) is located between the terminal portions (4a), and A low profile transformer, wherein the upper core (9) is joined to the upper end of the outer leg (8c) of the lower core (8).

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