JP2006032786A - Coil apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil apparatus wherein an axis of easy magnetization of a core 1 runs along the direction of a magnetic path in all regions, a binding structure of a plurality of core strips 2, 3 which constitute the core 1 is simple, and assembly is easy in a coil apparatus in which a coil is wound around periphery of the annular core 1 through a bobbin 4. <P>SOLUTION: In the coil apparatus, the core 1 is provided with first pair of core strips 2, 2 which correspond to two sides in parallel with each other out of four sides which constitute rectangular, and with second pair of core strips 3, 3 which correspond to other two sides in parallel with each other. These four core strips 2, 2, 3, 3 are arranged so that the respective easy axes are linked in a loop shape. Bobbins 4, 4 are formed on the first pair of core strips 2, 2, respectively by using insertion molding of synthetic resin. The four core strips 2, 2, 3, 3 are bound with each other by mutually linking and fixing both of the bobbins 4, 4. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a toroidal coil device in which a coil is wound around a ring core via a bobbin.

Conventionally, a toroidal type coil device equipped in various AC devices has a synthetic resin bobbin (9) around an annular core (9) formed by laminating a plurality of magnetic plates, for example, as shown in FIG. 93) to wind the coil (10) (see, for example, Patent Documents 1 and 2). The coil (10) is spirally wound around the outer peripheral surface of the bobbin (93) as shown in FIG.
As shown in FIG. 13, the core (9) is formed by abutting a pair of U-shaped core pieces (91) and (91) through magnetic gap portions (92) and (92) to form a loop-shaped magnetic path. Forming.
JP 2001-68352 A JP 2001-167949 A

However, the coil device shown in FIG. 11 is formed by laminating a plurality of U-shaped magnetic plates each of U-shaped core pieces (91) (91) as shown in FIG. Is manufactured by punching a strip-shaped steel plate material, and the easy magnetization axes of the core pieces (91) are aligned in the same direction in all regions as indicated by broken lines in FIG. There is a problem that a region in which the loop magnetic path and the easy axis of magnetization (9) are orthogonal to each other occurs.
In order to solve this problem, the U-shaped magnetic plate may be divided into three for each linear region, and the direction of the easy magnetization axis may be along the loop-shaped magnetic path. Therefore, there is a problem that the structure for fastening these core pieces together is complicated and the assembly process is complicated.

  Accordingly, an object of the present invention is to provide a coil device in which the easy axis of magnetization of the core is along the magnetic path direction over the entire region, the fastening structure of a plurality of core pieces constituting the core is simple, and the assembly is easy. It is.

The coil device according to the present invention is configured by winding a coil (10) through a bobbin (4) around an annular core (1) formed by laminating a plurality of magnetic plates.
The core (1) has a pair of first core pieces (2) (2) corresponding to two parallel sides of the four sides constituting the quadrangle and a pair of first core pieces corresponding to the other two parallel sides. The four core pieces (2), (2), (3), and (3) are arranged by connecting respective easy magnetization axes in a loop shape.
Bobbins are formed in the pair of first core pieces (2) and (2) by insert molding of synthetic resin, and the four cores are connected by fixing the bobbins of the first core pieces (2) and (2) to each other. The pieces (2), (2), (3), and (3) are fastened together.

  If a magnetic gap portion (22) is provided in the middle of the easy axis direction of each first core piece (2), a reactor is formed. If no magnetic gap portion (22) is provided, a transformer is formed. The

In the above coil device of the present invention, the four core pieces (2), (2), (3), and (3) are connected to each other in the form of a loop to form the core (1). The easy magnetization axis extends along the magnetic path direction over the entire region of the core (1).
In the manufacturing process of the coil device of the present invention, the bobbin that should surround the pair of first core pieces (2) and (2) is formed by insert molding of a synthetic resin, so that the bobbin is attached to the first core piece (2). The number of man-hours for mounting is small. However, the four core pieces (2), (2), (3), and (3) can be obtained by connecting and fixing the bobbins of the first core pieces (2) and (2) to each other. Since they are fastened together, the man-hours for core assembly are reduced.

In a specific configuration, the four core pieces (2), (2), (3), and (3) are formed on slopes whose both end faces along the easy magnetization axis are inclined with respect to the easy magnetization axis. The slopes are connected to face each other.
According to the specific configuration, the magnetic path formed in the corner portion of the core (1) substantially coincides with the easy magnetization axis.
Here, it is possible to provide a magnetic gap between the inclined surfaces of the at least two core pieces (2) and (3) facing each other.

In a specific configuration, the bobbins of the first core pieces (2) and (2) are connected and fixed to each other by ultrasonic welding.
According to this specific configuration, the process of connecting and fixing the bobbins of the first core pieces (2) and (2) to each other is simplified.

Further, in a specific configuration, the pair of bobbins (4) and (4) formed on the pair of first core pieces (2) and (2) are arranged at their both ends at the easy axis of the first core piece (2). A pair of hood portions (43) and (43) for accommodating both end portions in the direction, and the hood portions (43) and (43) facing each other of both bobbins (4) and (4) are provided with a second core piece (3 ) Are accommodated at both ends of the easy axis of magnetization, and both ends of the second core piece (3) are opposed to each other by the two hood portions (43) and (43) facing each other. ) Is inseparable from the end of the.
According to this specific configuration, by connecting and fixing the bobbins (4) and (4) to each other by, for example, ultrasonic welding, the pair of second core pieces (3) and (3) are simultaneously paired with the pair of first core pieces. (2) It will be fastened to (2).

In another specific configuration, each second core piece (3) is housed in the center of a resin boat-shaped member, and the first core piece (1) is inserted into both ends of the bobbin (5) formed on each first core piece (2). Both end portions in the easy axis direction of the core piece (2) protrude, and two end portions protruding in the same direction from the pair of first core pieces (2) and (2) are accommodated in both end portions of the boat-shaped member, As each hull form member is connected and fixed to both bobbins (5) and (5), both ends of the second core piece (3) are fastened to the ends of the first core pieces (2) and (2) on both sides thereof. ing.
According to this specific configuration, the bobbin (5) to surround each first core piece (2) can be formed by synthetic resin insert molding, and the hull form member to accommodate the second core piece (3). Can be easily formed by resin molding or insert molding, so the man-hours for mounting the bobbin (5) on the first core piece (2) and for mounting the hull form member on the second core piece (3) Man-hours are reduced.
And the process of connecting and fixing each ship-shaped member across the ends of the two bobbins (5) and (5) can be easily performed by, for example, ultrasonic welding.

In another specific configuration, the first core piece (2) and the second core piece (3) adjacent to each other are connected to each other in an L shape to form a pair of L-shaped core assemblies, A bobbin (6) is formed on the cylindrical core assembly by resin insert molding, and the two bobbins (6) and (6) are connected and fixed to each other, whereby a pair of L-shaped core assemblies are fastened together.
According to this specific configuration, the bobbin (6) that should surround the L-shaped core assembly can be easily formed by resin insert molding, but both bobbins (6) and (6) are, for example, ultrasonic welded. Since the four core pieces (2), (2), (3), and (3) are fastened to each other simply by connecting and fixing to each other, the number of assembling steps becomes very small as compared with the prior art.

In still another specific configuration, two ribs surrounding both ends of the first core piece (2) in the easy axis direction are provided at both ends of the bobbin (7) formed on each first core piece (2). (73) (73) is provided so that the second core piece (3) extends across the two ribs (73) (73) protruding in the same direction from the pair of first core pieces (2) (2). The covering connecting member (8) is installed, and the two ribs (73) (73) projecting in the same direction and both ends of the connecting member (8) are engaged with each other in an inseparable manner, and the second core piece (3 ) Are fastened to the ends of the first core pieces (2) and (2) on both sides thereof.
According to this specific configuration, the bobbin (7) which should surround each first core piece (2) can be easily formed by synthetic resin insert molding and accommodates each second core piece (3). The power connecting member (8) can be easily produced by molding a synthetic resin or pressing a metal plate.
Then, the second core piece (3) is moved to the first core pieces on both sides by a simple operation of pressing each connecting member (8) toward the ribs (73) and (73) of the two bobbins (7) and (7). (2) Can be fastened to (2).

  According to the coil device of the present invention, the easy magnetization axis of the core is along the magnetic path direction over the entire region, and the fastening structure of the plurality of core pieces constituting the core is simplified, and the assembly is also easy. .

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
First Embodiment As shown in FIG. 1, the coil device of the present embodiment has a synthetic resin bobbin (4) (4) around an annular core (1) formed by laminating a plurality of magnetic plates. The coils (10) and (10) are wound around.

As shown in FIG. 2, the core (1) is composed of a pair of first core pieces (2) (2) corresponding to two parallel sides of the four sides constituting the quadrangle, and the other two parallel sides. The four core pieces (2), (2), (3), and (3) have respective easy axes indicated by broken lines in the figure. They are connected in a loop shape to form a loop-shaped magnetic path.
Each first core piece (2) is configured by connecting and fixing core portions (21) and (21) having the same shape to each other via a magnetic gap portion (22).

Further, as shown in FIG. 3, the first core piece (2) and the second core piece (3) are inclined surfaces whose both end surfaces in the direction along the respective easy magnetization axes are inclined at about 45 degrees with respect to the easy magnetization axis ( 23) and (31), and these slopes are connected to each other so as to face each other.
The bobbin (4) is provided with a flange (42) projecting from both ends of the rectangular tube (41), and a rectangular box-shaped hood (43) projecting outside the flange (42). The whole is formed by a synthetic resin insert mold for the first core piece (2). Here, the two hood portions (43) (43) projecting in the same direction of both bobbins (4) and (4) have connecting chambers (44) and (44) opened in directions facing each other. The end of the first core piece (2) is accommodated in the connection chamber (44).
The two hood parts (43) and (43) projecting in the same direction of the pair of bobbins (4) and (4) accommodate both ends of the second core piece (3). In the portion (43), one connecting slope (23) of the first core piece (2) and one connecting slope (31) of the second core piece (3) are joined together.

Both the bobbins (4) and (4) have their end faces (42a) and (42a) of the respective flanges (42) and (42) abutted with each other and are connected and fixed to each other by ultrasonic welding. The integral coil device shown is constructed.
In the coil device, by connecting and fixing the two bobbins (4) and (4) to each other, both ends of the second core piece (3) are hood portions (43) (43) (bobbins (4) and (4)). 43) It is housed and held and is fastened to both first core pieces (2) and (2).
Therefore, a special part for fastening the second core piece (3) to both the cores (1) and (2) is unnecessary.

Note that the method of connecting and fixing the two bobbins (4) and (4) is not limited to ultrasonic welding, and various known connecting and fixing methods such as bonding using an adhesive and a locking structure using a hook are employed. I can do it.
Further, the magnetic gap portion (22) interposed in the middle of the first core piece (2) is omitted, and the connecting slope (23) of the first core piece (2) and the second core piece (3) facing each other are omitted. It is also possible to provide a magnetic gap between the inclined surfaces (31).

Second Embodiment As shown in FIG. 4, the coil device of the present embodiment has a synthetic resin bobbin (5) (5) around an annular core (1) formed by laminating a plurality of magnetic plates. The coils (10) and (10) are wound around. Here, the core (1) has the same configuration as the core (1) of the first embodiment.

As shown in FIG. 6, the bobbin (5) has flanges (52) projecting from both ends of a rectangular tube (51), and the whole is combined with the first core piece (2). It is formed by resin insert molding. Here, both ends of the first core piece (2) protrude from both ends of the bobbin (5).
Both bobbins (5) and (5) are connected and fixed to each other by ultrasonic welding such that the end faces (52a) and (52a) of the flanges (52) and (52) face each other.

On the other hand, a boat-shaped member (53) having a U-shaped cross section is formed on the second core piece (3) by an insert mold of synthetic resin for the second core piece (3).
The hull member (53) is installed across both bobbins (5) and (5) in a state where the second core piece (3) is accommodated, and the end surfaces (53a) and (53a) of the hull member (53) are both bobbins. (5) Joined to the flanges (52) and (52) of (5) and fixed by ultrasonic welding.
As a result, the two bobbins (5) and (5) and the two boat-shaped members (53) and (53) are connected and fixed to each other, whereby the pair of first core pieces (2) and (2) have the same direction. The connecting slopes (23) and (23) projecting from each other are joined to the connecting slopes (31) and (31) of the second core piece (3), respectively, to constitute an integral coil device shown in FIG.

  In the coil device, the bobbin (5) for accommodating the second core piece (3) and the boat-shaped member (53) for accommodating the second core piece (3) are both formed by resin insert molding, and these bobbins ( Since the connection between 5) and the boat-shaped member (53) is performed by ultrasonic welding, the assembly process is simple.

The second core piece (3) may be accommodated in a rectangular parallelepiped hull-shaped member (54) whose one surface is open as shown in FIG.
In addition, the method of connecting and fixing the two bobbins (5) and (5) to each other and the method of connecting and fixing the boat-shaped member (53) to both the bobbins (5) and (5) are not limited to ultrasonic welding, but an adhesive. Various well-known fixing methods, such as the used joining and the locking structure by a hook, are employable.
Further, the hull form member (53) is not limited to the structure formed by insert molding in the second core piece (3), but the structure in which the second core piece (3) is inserted and installed in the hull form member (53) pre-molded with resin is adopted. It is also possible to do.

Third Embodiment As shown in FIG. 7, the coil device of the present embodiment has a synthetic resin bobbin (6) (6) around an annular core (1) formed by laminating a plurality of magnetic plates. The coils (10) and (10) are wound around. Here, the core (1) basically has the same configuration as the core (1) of the first embodiment, but the first core piece (2) and the second core piece (3) as described later. ) To form a magnetic gap portion.

  As shown in FIG. 8, the bobbin (6) has flanges (62) projecting from both ends of the rectangular tube-shaped first tube part (61), and the first flange (62) A second cylindrical portion (64) coaxial with the cylindrical portion (61) and an L-shaped third cylindrical portion (63) projecting from the outside of the other flange (62). It is formed by a synthetic resin insert mold for the core piece (2).

Here, the 1st core piece (2) and the 2nd core piece (3) which mutually adjoin each other are connected in L shape, and a pair of L-shaped core assemblies are comprised, and each L-shaped core assembly is comprised. On the other hand, a bobbin (6) is formed by a resin insert mold.
Then, corresponding end faces (6a) and (6b) of both bobbins (6) and (6) are brought into contact with each other, and both end faces (6a) and (6b) are connected and fixed to each other by ultrasonic welding, as shown in FIG. An integral coil device is configured in which a pair of L-shaped core assemblies are fastened together.

  In the coil device, the bobbin (6) for accommodating the first core piece (2) and the second core piece (3) is formed by resin insert molding, and the two bobbins (6) (6) are mutually connected. Since the connection is performed by ultrasonic welding, the assembly process is simple.

Note that the end faces (6a) and (6b) of the bobbin (6) are notched, and the end faces of the first core piece (2) and the second core piece (3) are exposed, so that the two L-shaped core assemblies are formed. It is possible to omit the magnetic gap between them. Moreover, it is also possible to employ | adopt the structure which abbreviate | omitted the magnetic gap part (22) of the 1st core piece (2) as forming a magnetic gap part between two L-shaped core assemblies.
It is also possible to form a magnetic gap between the first core piece (2) and the second core piece (3) accommodated in the same bobbin (6). Furthermore, it is also possible to cut out only one end face (6a) of one bobbin (6) and form a magnetic gap portion by the other end face (6b).

Fourth Embodiment In the coil device of the present embodiment, as shown in FIG. 9, the bobbin (7) is provided with flanges (72) projecting from both ends of a rectangular tube (71), respectively, and a flange ( 72), ribs (73) made of three walls project from the outside, and the whole is formed by insert molding of synthetic resin to the first core piece (2). Here, both ends of the first core piece (2) are surrounded on three sides by ribs (73) and (73) of the bobbin (7). Locking windows (74) (74) are formed on the two wall surfaces of each rib (73).
The bobbins (7) and (7) are connected and fixed to each other by ultrasonic welding such that the end faces (72a) and (72a) of the flanges (72) and (72) face each other.

On the other hand, a metal connecting member (8) formed by projecting two side plate portions (82) and (82) on both sides of the flat plate portion (81) is attached to the second core piece (3). . Cut and raised pieces (83) and (83) project outwardly at two locations on both side plate portions (82) and (82) of the connecting member (8).
The connecting member (8) is installed straddling both bobbins (7) and (7) in a state in which the second core piece (3) is accommodated, and two cut and raised pieces (83) of each side plate portion (82). (83) is locked to the corresponding two locking windows (74) and (74) of the bobbins (7) and (7), thereby connecting the bobbins (7) and (7) to each other.
As a result, the end portions protruding in the same direction of the pair of first core pieces (2) and (2) are joined to the both end portions of the second core piece (3), respectively, and an integral coil device is configured.

  In the coil apparatus, the bobbin (7) is formed by resin insert molding, and the connecting member (8) is formed by press molding of a metal plate, and then the connecting member (8) is connected to both bobbins (7) (7). The coil device can be easily assembled by pressing against the ribs (73) and (73).

  In place of the metal connection member (8), a synthetic resin connection member (8) shown in FIG. 10 may be employed. The connecting member (8) has four side plate portions (82), (82), (84) and (84) projecting from the four sides of the flat plate portion (81), and has a long side plate portion (82). Two cut-and-raised pieces (83) and (83) are formed in the side plate portion (84) on the short side, and one cut and raised piece (85) is formed on the short side plate portion (84). These cut and raised pieces (83) and (85) are locked to corresponding locking windows (74) and (75) of the bobbin (7) shown in FIG. 9, and the connecting member (8) is connected to both bobbins. (7) Linked to (7).

  As described above, according to the coil device of the present invention, the magnetization of the core (1) constituted by the pair of first core pieces (2) (2) and the pair of second core pieces (3) (3). The easy axis extends along the magnetic path direction over the entire region, and the fastening structure of these core pieces (2), (2), (3), and (3) is simple and easy to assemble.

It is a perspective view which shows the coil apparatus of 1st Example of this invention. It is a front view of the core which comprises this coil apparatus. It is a disassembled perspective view of this coil apparatus. It is a perspective view of the coil apparatus of 2nd Example. It is a perspective view which shows an example of the boat-shaped member which accommodates the 2nd core piece in 2nd Example. It is a disassembled perspective view of this coil apparatus. It is a perspective view of the coil apparatus of 3rd Example. It is a disassembled perspective view of this coil apparatus. It is a disassembled perspective view of the coil apparatus of 4th Example. It is a perspective view which shows an example of the connection member in 4th Example. It is a perspective view of the conventional coil apparatus. It is a perspective view in the state where a coil is wound around a bobbin. It is a front view of the core which comprises the conventional coil apparatus.

Explanation of symbols

(1) Core
(10) Coil
(2) First core piece
(22) Magnetic gap
(23) Connecting slope
(3) Second core piece
(31) Connecting slope
(4) Bobbin
(43) Hood
(5) Bobbin
(53) Hull form member
(6) Bobbin
(7) Bobbin
(8) Connecting member

Claims (9)

  In a coil device in which a coil (10) is wound around a ring-shaped core (1) formed by laminating a plurality of magnetic plates via a bobbin (4), the core (1) forms a quadrangle. A pair of first core pieces (2) (2) corresponding to two parallel sides of the four sides, and a pair of second core pieces (3) (3) corresponding to the other two parallel sides, These four core pieces (2), (2), (3), and (3) are arranged by connecting the respective easy magnetization axes in a loop shape, and are connected to the pair of first core pieces (2) and (2). Each bobbin is formed by a synthetic resin insert mold, and the four core pieces (2), (2), (3), and (3) are obtained by connecting and fixing the bobbins of the first core pieces (2) and (2) to each other. A coil device that is fastened to each other.   The four core pieces (2), (2), (3), and (3) are formed with inclined surfaces that are inclined with respect to the easy magnetization axis, and both end surfaces in the direction along the easy magnetization axis are opposed to each other. The coil device according to claim 1, which is connected to each other.   The coil device according to claim 2, wherein a magnetic gap is interposed between the inclined surfaces of at least two core pieces (2) and (3) facing each other.   The coil device according to any one of claims 1 to 3, wherein bobbins of both first core pieces (2) and (2) are connected and fixed to each other by ultrasonic welding.   The pair of bobbins (4) and (4) formed on the pair of first core pieces (2) and (2) accommodate both ends of the first core piece (2) in the easy axis direction. It has a pair of hood parts (43) and (43), and both bobbins (4) and (4) are opposed to each other in the hood parts (43) and (43). Both ends are accommodated, and both ends of the second core piece (3) cannot be separated from the ends of the first core pieces (2) and (2) on both sides by both hood portions (43) and (43) facing each other. The coil device according to claim 1, wherein the coil device is constrained by the coil device.   Each 2nd core piece (3) is accommodated in the center part of a resin-made ship-shaped member, and magnetization of the 1st core piece (2) from the both ends of the bobbin (5) formed in each 1st core piece (2). Two ends protruding in the same direction from the pair of first core pieces (2) and (2) are accommodated in both ends of the boat-shaped member, and each boat-shaped member is fitted with both bobbins ( 5) The both ends of the second core piece (3) are fastened to the ends of the first core pieces (2) (2) on both sides thereof by being connected and fixed to (5). Item 5. The coil device according to any one of Items 4 to 5.   The first core piece (2) and the second core piece (3) adjacent to each other are connected to each other in an L-shape to form a pair of L-shaped core assemblies, and a resin insert is inserted into each L-shaped core assembly. The bobbin (6) is formed by a mold, and the pair of L-shaped core assemblies are fastened to each other by connecting and fixing the bobbins (6) (6) to each other. The coil apparatus as described in.   Two ribs (73) and (73) surrounding both ends of the first core piece (2) in the easy magnetization axis direction protrude from both ends of the bobbin (7) formed on each first core piece (2). A connecting member (8) covering the second core piece (3) is installed across the two ribs (73) and (73) protruding in the same direction from the pair of first core pieces (2) and (2). The two ribs 73, 73 projecting in the same direction and both ends of the connecting member 8 are inseparably engaged with each other, and both ends of the second core piece 3 are on both sides thereof. The coil device according to any one of claims 1 to 4, wherein the coil device is fastened to an end of the first core piece (2) (2).   The coil device according to any one of claims 1 to 8, wherein each first core piece (2) is provided with a magnetic gap portion (22) at an intermediate position in the direction of the easy axis of magnetization.

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