JP2007165348A - Transformer and inverter device loading the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a transformer in which miniaturization and pressure resistance correspondence are realized and which is superior in productivity, and to provide an inverter device that has the transformer loaded. <P>SOLUTION: The transformer is provided with a bobbin having a winding part winding a coil, first wiring and second wiring which are wound to the winding part of the bobbin, an inner core inserted into the inner side of the bobbin, an outer core arranged outside the bobbin, and a heat resistant member for filling a part between the primary/secondary windings and the outer core with an insulating material. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a transformer and an inverter device equipped with the transformer.

  Conventionally, a transformer in which an insulating material is filled in an insulating case after a transformer including a coil bobbin, a core, a primary coil, and a secondary coil is incorporated in the insulating case is disclosed (for example, Patent Document 1).

JP-A-6-163278

  38 to 43 are hexahedral views showing the internal structure of a conventional transformer. Here, 1 is a bobbin, 2 is a terminal of the bobbin, 3 is a high voltage winding portion of the bobbin terminal, 4 is a high voltage winding, 5 is a low voltage winding, 7 is an inner core inserted into the bobbin, and 8 is an inner core. The outer core 9 is combined with the core adhesive 9.

  44 to 49 are six-sided views showing the appearance of a transformer in which an insulating material is filled in the insulating case after the internal structure of these transformers is incorporated in the insulating case. Here, 10 is an insulating case, and 11 is an insulating material vacuum-filled in the insulating case.

  However, such a configuration has the following problems. That is, the space required for downsizing of transformers mounted on notebook computers and liquid crystal monitors and inverter power supplies using the same is becoming increasingly demanding year by year, and further, cost reduction and simplification of the assembly process are required. . In the prior art, the insulation case is filled with an insulating material to cope with a high breakdown voltage. However, such a method cannot meet the recent demands for miniaturization and cost reduction. On the other hand, if the transformer is exposed without filling with an insulating material and without using an insulating case, the transformer can be reduced in size, but this cannot cope with a high breakdown voltage. That is, the conventional technology cannot achieve both miniaturization and high breakdown voltage compatibility.

  This will be specifically described as follows. That is, since it is necessary to fill the insulating material to cope with a high breakdown voltage, an extra size corresponding to the case is required to accumulate the insulating material, and the outer shape of the transformer is increased. Moreover, since it is necessary to ensure the strength of the case when filling the insulating material, the case thickness is required and the transformer outer shape is enlarged. Further, if the insulating material adheres to the terminal, it causes a soldering failure. In order to prevent this, the terminal must be set at a position outside the case, and the transformer outer shape becomes large. In addition, the amount of the insulating material that is injected needs to be sufficient to hide the transformer. Further, when the insulating material is vacuum-filled, it is necessary to cope with the volume expansion caused by the firing, so the height of the case is also necessary. However, the case outline becomes larger. In addition, since the amount of injected insulating material increases, it also hinders cost reduction and weight reduction.

  Furthermore, when injecting the insulating material, in order to prevent the case overflowing of the insulating material due to volume expansion, multiple times (for example, two times or three times) of injection work and vacuum defoaming work may be required. The process becomes complicated. Further, when the insulating material adheres to the soldered portion of the terminal, it is necessary to remove the insulating material, which further complicates the assembly process.

  An object of this invention is to provide the transformer excellent in productivity and the inverter apparatus carrying this, in view of the said subject.

  In order to solve the above-described problems, the present invention provides a bobbin having a winding part for winding a coil, a primary winding and a secondary winding wound around the winding part of the bobbin, and an inner side of the bobbin. An inner core, an outer core disposed outside the bobbin, and a heat-resistant member for filling an insulating material between the primary winding and the secondary winding and the outer core.

  ADVANTAGE OF THE INVENTION According to this invention, it becomes possible to provide the transformer excellent in productivity, and the inverter apparatus carrying this.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

  FIGS. 1-6 is a hexahedral figure which shows the internal structure of the trans | transformer which concerns on the 1st Example of this invention, and has shown the state before filling with an insulating material. Here, 1 is a bobbin, 2 is a terminal of the bobbin, 3 is a high voltage winding portion of the bobbin terminal, 4 is a high voltage winding, 5 is a low voltage winding, 6 is a heat resistant tape, and 7 is an inner core inserted into the bobbin. , 8 is an outer core combined with the inner core, and 9 is an adhesive for the core. The shaded area in FIGS. 4 to 6 shows a portion covered with heat-resistant tape.

  7 to 12 are six-sided views showing the appearance of the transformer after a necessary portion is filled with an insulating material using a heat-resistant tape. Here, 11 is an insulating material vacuum-filled in a heat-resistant tape. 10-12 show the part covered with the heat-resistant tape, and the double hatched part shows the filled insulating material.

  FIG. 13 is a diagram showing a cross section of a transformer filled with an insulating material. Here, 12 is a cross section of the bobbin, 13 is a cross section of the high voltage winding / low voltage winding, 14 is a cross section of the inner core, 15 is a cross section of the outer core, 16 is a cross section of the heat-resistant tape, and 17 is a vacuum-filled insulating material. The cross-section, a, indicates a portion (between the high-voltage winding and the low-voltage winding and the outer core) that particularly requires vacuum filling with an insulating material.

  In this embodiment, the insulating material is vacuum-filled without using an insulating case as in the prior art. That is, in the prior art, since there is an insulating case, it was not possible to reduce the size, but in this embodiment, it is possible to reduce the size by removing it. In addition, since it is sufficient to fill the insulating material only in the necessary parts (between the high-voltage winding and the low-voltage winding and the outer core), not only miniaturization but also cost reduction can be realized by filling only the relevant part. be able to.

  The reason why the insulating case can be eliminated as in this embodiment is that the heat-resistant tape can be substituted for the insulating case through an assembly process described later. With such a configuration, it is possible to contribute to downsizing by the amount of the insulating case.

  Specifically, the size can be reduced by about 2 mm in the width direction, about 2 mm in the length direction, and about 3 mm in the height direction. Compared with the conventional product → the product corresponding to the present example by taking the actual product size as an example, the width direction is 11 mm → 9 mm (about 18% reduction), the length direction is 37 mm → 35 mm (about 5% reduction), high In the vertical direction, the size can be reduced from 8 mm to 5 mm (reduction of about 38%). This makes it possible to keep the overall volume to about 48% of the conventional product (= (9/11) × (35/37) × (5/8)). It means that it can be halved. As is clear from the above, the effect of downsizing according to the present embodiment is extremely large.

  Moreover, in spite of achieving such a miniaturization, the withstand voltage can be improved by about 300 V (rms) as compared with a conventional transformer not filled with an insulating material. Compared with the conventional product → the product corresponding to the present embodiment by taking the pressure resistance of the actual product as an example, the performance improvement of 1400 V (rms) → 1700 V (rms) (an improvement of about 21%) is aimed at. It became possible. As a result, the product specifications can be sufficiently cleared and a sufficient margin of pressure resistance performance can be provided.

  As described above, in this embodiment, the transformer can be significantly reduced in size and sufficient withstand voltage performance can be achieved, and both contradictory performances of downsizing and high withstand voltage can be achieved.

  As mentioned earlier, in recent years, the space required for downsizing transformers and inverter power supplies that use them in notebook computers and LCD monitors has become stricter year by year, and at the same time has high pressure resistance. It is requested. According to the present embodiment, it is possible to satisfy both of these requirements, which is extremely effective.

  In addition, although the method of filling an insulating material using a heat-resistant tape is shown here, the present invention is not limited to this, and a member other than the heat-resistant tape may be used. For example, aramid paper may be folded into a U shape as a substitute other than heat-resistant tape. Further, other members may be used as long as they can realize heat resistance and downsizing (thinning).

  Next, an outline of a method for manufacturing the transformer of this embodiment will be described.

  (1) The high voltage winding 4 and the low voltage winding 5 are wound around the bobbin 1.

  (2) Insert the inner core 7 into the bobbin 1.

  (3) An adhesive is applied to the core bonding surface 24 (see FIG. 14).

  (4) The outer core 8 is combined.

  (5) The adhesive is cured.

  (6) Affix the heat-resistant tape 6 on the outside of the transformer.

(7) Apply an insulating material leakage prevention adhesive to 25 (see FIG. 14).
(8) The transformer 18 is fitted into the jig 19 for filling the insulating material (see FIG. 15). In FIG. 15, 18 is a transformer before filling with an insulating material, and 19 is a jig (base) for filling the transformer with an insulating material.

  (9) A jig 20 for filling the transformer with an insulating material is fitted from above the jig 19 (see FIGS. 16 and 17). FIG. 17 is a view showing a state in which the jig 20 is fitted into the jig 19. With the jig 19 and the jig 20 fitted, the high voltage winding, the low voltage winding, the outer core and the like of the transformer 18 are exposed from the top.

  (10) An insulating material 21 is injected from above the jig 19 and the jig 20 (see FIG. 18). In this state, the transformer 18 is configured such that the heat-resistant tape 6 surrounds the transformer in a concave shape, and the insulating material filled from above is accumulated around the transformer 18 by the heat-resistant tape 6.

  (11) Perform vacuum defoaming.

  (12) Remove the jig 20 and fit the jig 22. The jig 22 is a jig (lid) for adjusting the outer shape and stabilizing the outer dimension of the transformer (see FIGS. 19 and 20). FIG. 20 shows a state in which the jig 22 is fitted.

  (13) The insulating material is cured.

  (14) Remove the jig 22 and take out the transformer 23. The transformer 23 is in a state where an insulating material is vacuum-filled and cured (see FIG. 21).

Through the assembly process as described above, it is possible to configure a transformer that is filled with an insulating material while eliminating the need for an insulating case, and that is miniaturized and capable of handling a high breakdown voltage. Further, in the prior art, it may be necessary to repeat filling of the insulating material and vacuum degassing a plurality of times, and the assembly process can be simplified as compared with such a case.

  22 to 27 are hexahedral views showing the internal structure of the transformer according to the second embodiment of the present invention, showing a state before filling with an insulating material. In the first embodiment, the heat-resistant tape 6 is used, but in the present embodiment, a configuration in which this is not used is shown.

  Here, 1 is a bobbin, 2 is a terminal of the bobbin, 3 is a high voltage winding portion of the bobbin terminal, 4 is a high voltage winding, 5 is a low voltage winding, 7 is an inner core inserted into the bobbin, and 8 is an inner core. The outer core 9 is combined with the core adhesive 9.

  FIGS. 28 to 33 are hexahedral views showing the appearance of the transformer after a necessary part is filled with an insulating material. Here, 11 is an insulating material in which the transformer is vacuum-filled. 29 and 31 to 33 indicate the filled insulating material.

  FIG. 34 is a diagram showing a cross section of a transformer filled with an insulating material. Where 12 is the cross section of the bobbin, 13 is the cross section of the high voltage winding / low voltage winding, 14 is the cross section of the inner core, 15 is the cross section of the outer core, 17 is the cross section of the vacuum-filled insulating material, and a is the cross section of the insulating material The part which needs especially vacuum filling (between a high voltage | pressure winding and a low voltage | pressure winding-outer core) is shown.

  In this embodiment, the insulating material is vacuum-filled without using an insulating case as in the prior art. That is, in the prior art, since there is an insulating case, it was not possible to reduce the size, but in this embodiment, it is possible to reduce the size by removing it. In addition, since it is sufficient to fill the insulating material only in the necessary parts (between the high-voltage winding and the low-voltage winding and the outer core), not only miniaturization but also cost reduction can be realized by filling only the relevant part. be able to.

  The reason why the insulating case can be made unnecessary as in this embodiment is that the insulating material can be filled without an insulating case by an assembly process described later. With such a configuration, it is possible to contribute to downsizing by the amount of the insulating case.

  Specifically, the size can be reduced by about 2 mm in the width direction, about 2 mm in the length direction, and about 3 mm in the height direction. Compared with the conventional product → the product corresponding to the present example by taking the actual product size as an example, the width direction is 11 mm → 9 mm (about 18% reduction), the length direction is 37 mm → 35 mm (about 5% reduction), high In the vertical direction, the size can be reduced from 8 mm to 5 mm (reduction of about 38%). This makes it possible to keep the overall volume to about 48% of the conventional product (= (9/11) × (35/37) × (5/8)). It means that it can be halved. As is clear from the above, the effect of downsizing according to the present embodiment is extremely large.

  Moreover, in spite of achieving such a miniaturization, the withstand voltage can be improved by about 300 V (rms) as compared with a conventional transformer not filled with an insulating material. Compared with the conventional product → the product corresponding to the present embodiment by taking the pressure resistance of the actual product as an example, the performance improvement of 1400 V (rms) → 1700 V (rms) (an improvement of about 21%) is aimed at. It became possible. As a result, it is possible to sufficiently clear the use of the product and to have a sufficient margin of pressure resistance performance.

  As described above, in this embodiment, the transformer can be significantly reduced in size and sufficient withstand voltage performance can be achieved, and both contradictory performances of downsizing and high withstand voltage can be achieved.

  As mentioned earlier, in recent years, the space required for downsizing transformers and inverter power supplies that use them in notebook computers and LCD monitors has become stricter year by year, and at the same time has high pressure resistance. It is requested. According to the present embodiment, it is possible to satisfy both of these requirements, which is extremely effective.

  Next, an outline of a method for manufacturing the transformer of this embodiment will be described. The assembly method is almost the same as that of the first embodiment described above, except that heat-resistant tape is not used.

  (1) The high voltage winding 4 and the low voltage winding 5 are wound around the bobbin 1.

  (2) Insert the inner core 7 into the bobbin 1.

  (3) An adhesive is applied to the core bonding surface 24 (see FIG. 35).

  (4) The outer core 8 is combined.

  (5) The adhesive is cured.

(6) Apply an insulating material leakage prevention adhesive to 25 (see FIG. 35).
(7) The transformer 18 is fitted into the jig 19 for filling the insulating material (see FIG. 15). In FIG. 15, 18 is a transformer before filling with an insulating material, and 19 is a jig (base) for filling the transformer with an insulating material.

  (8) The jig 20 for filling the transformer with the insulating material is fitted from above the jig 19 (see FIGS. 16 and 17). FIG. 17 is a view showing a state in which the jig 20 is fitted into the jig 19. With the jig 19 and the jig 20 fitted, the high voltage winding, the low voltage winding, the outer core and the like of the transformer 18 are exposed from the top.

  (9) An insulating material 21 is injected from above the jig 19 and the jig 20 (see FIG. 18). In this state, the jig 19 is configured to surround the transformer, and the insulating material filled from above is accumulated around the transformer 18 by the jig 19.

  (10) Perform vacuum defoaming.

  (11) Remove the jig 20 and fit the jig 22. The jig 22 is a jig (lid) for adjusting the outer shape and stabilizing the outer dimension of the transformer (see FIGS. 19 and 20). FIG. 20 shows a state in which the jig 22 is fitted.

  (12) The insulating material is cured.

  (13) Remove the jig 22 and take out the transformer 23. The transformer 23 is in a state where an insulating material is vacuum-filled and cured (see FIG. 21).

  Through the assembly process as described above, it is possible to configure a transformer that is filled with an insulating material while eliminating the need for an insulating case, and that is downsized and capable of handling a high breakdown voltage. Further, in the prior art, it may be necessary to repeat filling of the insulating material and vacuum degassing a plurality of times, and the assembly process can be simplified as compared with such a case.

  In addition, since the heat-resistant tape is unnecessary in this embodiment, a process of applying the heat-resistant tape can be omitted, and the assembly process can be simplified. Further, the cost for the heat-resistant tape is not required, so that the cost can be reduced.

  Next, FIG. 36 shows an inverter device equipped with the transformer described in the first or second embodiment, and FIG. 37 shows a display device equipped with a display screen such as a liquid crystal equipped with such an inverter device.

  In FIG. 36, the control circuit controls the entire apparatus, and controls an operation circuit such as a drive circuit, for example. The drive circuit is a circuit that operates the transformer. The transformer outputs a voltage for turning on the backlight.

  In FIG. 37, the signal circuit processes the video signal to display the video on the liquid crystal panel. The control circuit controls the entire apparatus, and controls, for example, an inverter power supply. The inverter power supply turns on the backlight. The backlight illuminates the liquid crystal panel. In addition, the liquid crystal panel plays a role as a display unit for displaying an image.

  As described above, according to the embodiment of the present invention, it is possible to provide a transformer with excellent productivity and an inverter device equipped with the transformer.

6 is a six-sided view showing the internal structure of the high-voltage transformer. 6 is a six-sided view showing the internal structure of the high-voltage transformer. Sixth view showing the internal structure of the high-voltage transformer. Sixth view showing the internal structure of the high-voltage transformer, part 4 Sixth view showing the internal structure of the high-voltage transformer, part 5 Sixth view showing the internal structure of the high voltage transformer. 6 is a six-sided view illustrating an appearance of a high-voltage transformer after filling with an insulating material. 6 is a six-sided view illustrating the appearance of the high-voltage transformer after filling with an insulating material. 6 is a six-sided view showing the appearance of the high-voltage transformer after filling with an insulating material. 6 is a six-sided view showing the appearance of the high-voltage transformer after filling with an insulating material. 6 is a hexahedral view showing the appearance of the high-voltage transformer after filling with an insulating material. 6 is a six-sided view showing the appearance of the high-voltage transformer after filling with an insulating material. The figure which shows the cross section of the high voltage | pressure transformer after insulating material filling. The figure which shows the high voltage transformer before insulation material filling. The figure when inserting a transformer in a jig. FIG. 1 is a diagram showing a state in which a transformer is fitted in a jig. The figure 2 which shows the state which inserted the transformer in the jig. The figure when it is filled with an insulating material. Figure 1 when shaping a transformer. Figure 2 when shaping a transformer. The figure which shows the transformer completed product with which the insulating material was filled. 6 is a six-sided view showing the internal structure of the high-voltage transformer. 6 is a six-sided view showing the internal structure of the high-voltage transformer. Sixth view showing the internal structure of the high-voltage transformer. Sixth view showing the internal structure of the high-voltage transformer, part 4 Sixth view showing the internal structure of the high-voltage transformer, part 5 Sixth view showing the internal structure of the high voltage transformer. 6 is a six-sided view illustrating an appearance of a high-voltage transformer after filling with an insulating material. 6 is a six-sided view illustrating the appearance of the high-voltage transformer after filling with an insulating material. 6 is a six-sided view showing the appearance of the high-voltage transformer after filling with an insulating material. 6 is a six-sided view showing the appearance of the high-voltage transformer after filling with an insulating material. 6 is a hexahedral view showing the appearance of the high-voltage transformer after filling with an insulating material. 6 is a six-sided view showing the appearance of the high-voltage transformer after filling with an insulating material. The figure which shows the cross section of the high voltage | pressure transformer after insulating material filling. The figure which shows the high voltage transformer before insulation material filling. The block diagram of the inverter apparatus incorporating a transformer. The block diagram of display apparatuses, such as a liquid crystal screen incorporating a transformer. 6 is a six-sided view showing the internal structure of a conventional transformer. 6 is a six-side view showing the internal structure of a conventional transformer. 6 is a six-sided view showing the internal structure of a conventional transformer. 6 is a six-sided view showing the internal structure of a conventional transformer. 6 is a hexahedral view showing the internal structure of a conventional transformer. Sixth view showing the internal structure of a conventional transformer. FIG. 1 shows a transformer incorporated in a conventional insulating case. The figure 2 which shows the transformer built into the conventional insulation case. The figure 3 which shows the transformer built into the conventional insulation case. FIG. 4 is a diagram showing a transformer incorporated in a conventional insulating case. FIG. 5 is a diagram showing a transformer incorporated in a conventional insulating case. FIG. 6 is a diagram showing a transformer incorporated in a conventional insulating case.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Bobbin, 2 ... Terminal of bobbin, 3 ... High voltage winding part of bobbin terminal, 4 ... High voltage winding, 5 ... Low voltage winding, 6 ... Heat-resistant tape, 7 ... Inner core, 8 ... Outer core, 9 ... core adhesive.

Claims (8)

A bobbin having a winding part for winding a coil;
A primary winding and a secondary winding wound around a winding portion of the bobbin;
An inner core inserted inside the bobbin;
An outer core disposed outside the bobbin;
A heat-resistant member for filling an insulating material between the primary and secondary windings and the outer core;
A transformer characterized by comprising. The transformer according to claim 1, wherein
A transformer characterized in that insulation between the primary and secondary windings and the outer core is ensured by filling the insulating material. The transformer according to claim 1, wherein
A space between the primary winding and the secondary winding and the outer core is covered with the heat-resistant member in a U-shape, and the U-shaped portion is filled with the insulating material. Transformer. The transformer according to claim 1, wherein
The heat-resistant member is a thin tape-like member in which an insulating material is filled between the primary and secondary windings and the outer core. The transformer according to claim 1, wherein
The transformer, wherein the heat-resistant member is heat-resistant tape or aramid paper. The transformer according to claim 1, wherein
The transformer, wherein the insulating material is vacuum-filled between the primary and secondary windings and an outer core. A transformer according to any one of claims 1 to 6;
A drive circuit for operating the transformer;
An inverter device comprising: a control circuit that controls the drive circuit. A display unit having a backlight and displaying images;
The inverter device according to claim 7, wherein the backlight is lit.
And a control circuit for controlling the display unit and the inverter device.

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