JP2008028315A - Winding coil and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a small winding coil easy to fabricate by easy work, regardless of the number of winding of the coil without decreasing inductance value or causing damage of wire, and to provide its manufacturing method. <P>SOLUTION: The winding coil has a core 1 in which four plate shaped core strips of identical shape made of magnetic substance are jointed; and a bobbin 2 made up of four connected bobbin objects of identical shape in which flanges are formed at the both ends of winding core, a projection is formed at an end face of the flange among these flanges, and a recessed groove for engaging the projection is formed at the other flanges. Each core member is inserted to the winding core. The edge face of the core member on the short side is fitted mutually to the edge face on the long side of another core member, which is different from the core member, and the joint of the core members is coated with the same material as the magnetic substance which constitutes the core member to form the core 1 having a closed magnetic circuit. Winding wire 15 is formed around the bobbin object with a conductor 10, the projection is engaged with the recessed groove, and the core member and the bobbin object are assembled in a rectangular form in the winding coil. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a winding coil used in an electric circuit such as a consumer or industrial electronic device and a method for manufacturing the same, and more particularly to a rod-shaped core using a magnetic material in which a plurality of types of soft magnetic powder and resin are mixed. The present invention relates to a winding coil that is formed into a closed magnetic circuit core by being inserted into a bobbin that has been molded into a winding, and a manufacturing method thereof.

  The wound coil is generally a toroidal coil (single-layer circular coil with a circular cross section), and the toroidal coil is configured by winding a conducting wire around a ring-shaped core. Such a toroidal coil requires a lot of work and man-hours because it requires an operation of winding a conducting wire around the ring core one turn at a time.

  In order to solve this problem, a technique described in Patent Document 1 has been proposed. In this technique, as shown in FIG. 13, a conductive wire is wound in advance to form a cylindrical coil 101, and each of the divided ring cores 102 is inserted into the air core portion of the cylindrical coil 101. At this time, the ring core 102 is inserted into the air core portion of the cylindrical coil 101 while bending the cylindrical coil 101 into a ring shape. Thereafter, the split surfaces of the ring core 102 were joined to form a toroidal coil having an annular shape as a whole.

  However, since the cylindrical coil 101 formed by winding a conducting wire in advance needs to be bent into a ring shape, the one described in Patent Document 1 described above can be used only when the number of turns of the coil is small. There was a drawback.

  Further, when the ring core 102 is inserted into the air core part, the conducting wire is easily damaged, so that the assembling work is not easy.

  Therefore, as shown in FIG. 14, by using the deformed bobbin 112 and passing through the divided ring core 113 to form an annular shape, a simple winding operation is possible regardless of the number of turns of the coil, and the conductor wire Japanese Patent Application Laid-Open No. H10-228561 describes a technique related to the toroidal coil 111 that does not cause any damage. However, in this example, because of the divided ring core, the inductance value is low, and the shape of the deformed bobbin is a substantially trapezoidal cross-sectional shape having a long cylindrical portion 112a and a short side portion 112b. It is necessary to fix the hollow portion of the bobbin and the straight shaft core when winding the conducting wire, and to connect each bobbin into a ring shape, a ring core having a certain size of inner diameter is required. Therefore, it has been difficult to reduce the shape.

JP 2001-068364 A (FIG. 6) JP 2004-158684 A (FIG. 1)

  As described above, the conventional winding coil has a drawback that it takes a lot of work and man-hours because it requires an operation of winding the conducting wire around the ring core of the toroidal coil one turn at a time. Further, since the conductor wire is easily damaged, there is a problem that the assembly work is not easy and the inductance value becomes low when the split coil is used. Moreover, since it was ring-shaped, it was an obstacle to miniaturization.

  The object of the present invention is that it can be manufactured by an easy operation regardless of the number of windings of the coil, and further, does not cause damage to the conductive wire, and further, the inductance value does not decrease, and a small-sized winding coil and its manufacture It is to provide a method.

  According to the present invention, four rod pieces or plate-shaped core pieces of the same shape made of a magnetic material, and ridges are formed at both ends of the winding core, and one end surface of the ridge and the other ridge among the ridges. Four bobbin bodies of the same shape provided with engaging portions that fit together, the core pieces are respectively inserted into the winding cores, and the end face on the short side of the core piece is the core piece Bonding each other to the end face of the end portion on the long side of different core pieces, applying the same material as the magnetic body to the joint portion of the core piece to form a closed magnetic path core, and winding the bobbin body, A winding coil is obtained by fitting the locking portion and combining the core piece and the bobbin body in a rectangular shape.

  Further, according to the present invention, the core piece is molded into a rod shape or a plate shape by curing a magnetic material obtained by mixing a plurality of types of soft magnetic materials and a resin into a compression mold or a box-shaped mold. The above-described winding coil is obtained.

  According to the present invention, there is also provided a winding coil manufacturing method in which four core pieces having the same shape and four bobbin bodies having the same shape are combined in a rectangular shape, comprising a plurality of types of soft magnetic materials and resins. A step of molding the mixed magnetic body into powder or molding into a box-shaped mold and then curing to form the core piece into a rod-like or plate-like shape, forming ridges at both ends of the core of the bobbin body, A locking portion that fits the end surface of one of the flanges and the other flange, and winding the winding core, and then fitting the locking portion; and Each of the end pieces on the short side of the core piece is joined to the end face of the end of the long side of the core piece different from the core piece, and the same material as the magnetic material is joined to the joint portion of the core piece. The manufacturing method of the winding coil characterized by including the process of apply | coating and forming a closed magnetic circuit core is obtained.

  That is, according to the present invention, a magnetic body containing a plurality of types of soft magnetic materials and a nonmagnetic resin is compacted or cast into a box-shaped mold and then cured to mold a core piece into a rod or plate shape, A bobbin body having an inner diameter sufficient to allow a rod-shaped or plate-shaped core piece to be inserted is wound with a round wire or a rectangular wire (conductor) having a conductive coating on a conductive wire to a predetermined number of turns, and then each bobbin body The rod-shaped or plate-shaped core piece is inserted, and a magnetic material including a plurality of types of soft magnetic materials and non-magnetic resin, which is the same material as the core piece, is applied to the joint portion of the core pieces and then cured to be integrated. It is possible to realize a winding coil that forms a closed magnetic circuit coil with a core.

  The winding coil according to the present invention uses, for example, a bobbin body provided with a convex protrusion on one side of the opposite side and a concave groove on the other side as a locking portion to be fitted to each other. Since the convex protrusion and the concave groove can be fitted and fixed and processed by automatic winding by a machine, a manual process such as winding a ring-shaped coil can be eliminated.

  In addition, in the winding coil of the present invention, the bobbin bodies are connected to each other in a rectangular shape, so that it is not necessary to secure a certain inner diameter as in the case of the ring core, and the shape can be reduced and the size can be reduced. Can be realized.

  In the wound coil of the present invention, another core is installed in the L shape near the tip of the rod-like or plate-like core, another core is installed at the tip of the core, and another core is installed. Thus, by forming a closed magnetic circuit coil, it is possible to assemble with a core having the same shape, and further, by providing a large space in the inner diameter portion, it is possible to alleviate heat generation when a current flows through the winding coil.

  Furthermore, in the present invention, a magnetic material containing a plurality of types of soft magnetic materials and a non-magnetic resin is compacted or cast into a box-shaped mold and then cured to mold a core piece into a rod or plate shape, and a conductor is formed on the bobbin. After winding a predetermined number of turns, a core piece is inserted into each of the bobbin bodies, and a magnetic material of the same type as the core piece is applied and cured at the joint of the core pieces to form a closed magnetic circuit core. Thereby, the fall of an inductance can be prevented.

  Further, in the present invention, normal pressure casting can be performed, and manufacturing in a core shape that is more flexible than conventional pressure molding is possible.

  Embodiments of the present invention will be described below in detail with reference to the drawings.

(Embodiment 1)
FIG. 1 is an external perspective view of a winding coil according to the first embodiment of the present invention. FIG. 2 is a plan view of the winding coil according to the first embodiment of the present invention. FIG. 3 is a plan view showing a joined state of the cores according to the first embodiment of the present invention. FIG. 4 is a flowchart showing a manufacturing process of the core in the first embodiment of the present invention. FIG. 5 is a development view for explaining the bobbin according to the first embodiment of the present invention. FIG. 5 (a) is a plan view, FIG. 5 (b) is a left side view, and FIG. FIG. 5D is a right side view, and FIG. 5E is a bottom view. FIG. 6 is a plan view showing a fitting state of the uneven portion of the bobbin in the first embodiment of the present invention. FIG. 7 is a perspective view showing a state in which the axis of the automatic winding machine according to the first embodiment of the present invention is set on a bobbin. FIG. 8 is a perspective view for explaining a method of winding a conductor around a bobbin in the automatic winding machine according to the first embodiment of the present invention. FIG. 9 is a perspective view showing a state after the assembly of the bobbin around which the conductor is wound in the first embodiment of the present invention.

  As shown in FIGS. 1 and 2, the winding coil of the present invention has a core 1 in which four rod-shaped or rod-shaped core pieces are joined, and a conductor 10 wound around respective winding frames. The bobbin 2 is a combination of bodies, and the end of the winding is connected to the pin terminal 5 and fixed. Here, the pin terminal 5 shows only the terminal for connecting the end of the winding.

  As shown in FIG. 3, the core 1 is a combination of four rod-like or plate-like core pieces, each short side is joined to the end of the long side, and a magnetic material is applied to the joint 11. It is then hardened to form a closed magnetic circuit core.

  First, the core manufacturing method will be briefly described with reference to the flowchart of the process shown in FIG. Here, normal pressure casting will be described. As for the core, the material described in Japanese Patent Application No. 2006-014699 previously proposed by the present applicant can be used.

  As shown in FIG. 4, the core made of a magnetic material first weighs the first magnetic powder and the coupling agent (step S1). Next, these are mixed and the first magnetic powder and the coupling agent are blended (step S2). The second magnetic powder and the third magnetic powder are weighed (step S3). Further, the composite material in step S2, the second magnetic powder, and the third magnetic powder are mixed (step S4). Thereafter, the resin powder is weighed (step S5). This is mixed with the composite material of step S4 (step S6). Next, the composite material in step S6 is heated to dissolve the resin component and to provide fluidity (step S7). The heated composite material is cast into a mold for molding (step S8). The cast composite material is heated and cured (step S9). After natural cooling, the hardened magnetic body is taken out of the mold to complete a rod-like or plate-like core.

  The core material is a composite material in which a mixture of a plurality of types of soft magnetic powder and resin is solidified, and in the composite material in which the volume percentage of the plurality of types of powder is 60 to 90 vol% with respect to the total volume of the composite material The second ratio D2 / D1 of the average particle diameter D2 of the second magnetic powder to the average particle diameter D1 of the first magnetic powder occupying most of the plurality of types of powders is in the range of 1/400 to 1/20. The magnetic powder is contained at 1.0 vol% or more with respect to the total volume of the composite material. The third magnetic powder is such that the ratio D3 / D1 of the average particle diameter D3 of the third magnetic powder to the average particle diameter D1 of the first magnetic powder is in the range of 1/20 to 1/2. 1.0 vol% or more is included. The second magnetic powder can be spherical. Moreover, as a material of the first magnetic powder, it is preferable to use at least one of an Fe—Si based alloy, a Fi—Si—Al based alloy, an iron based amorphous alloy, and a cobalt based amorphous alloy. As the first magnetic powder, for example, Fe-Si alloy, etc., as the second magnetic powder, similarly Fe-Si alloy, etc., as the third magnetic powder, Fe-Cr-Si alloy, etc., as the resin, thermosetting An epoxy resin or the like can be used.

  As shown in FIGS. 5 and 6, the bobbin 2 has a plurality of bobbin bodies made of a flexible material having an inner diameter sufficient to allow the rod-shaped core to pass therethrough, and has a winding core (hollow part 7). As the engaging portions that are provided and fitted to each other, for example, a convex protrusion 3 is provided on one side of the opposite side, and a concave groove 4 is provided on the other side, and each bobbin body has a convex protrusion. 3 and the concave groove 4 can be fitted and fixed. Moreover, the pin terminal 5 is formed in the pin terminal planting part provided in the right and left both sides of the same collar so that a front-end | tip may protrude at upper and lower ends. As an example of the locking portion, an example is shown in which a convex protrusion is provided on the end face of one hook, and a concave groove in which the protrusion can be fitted is provided in the other hook. Convex protrusions may be provided on the ridges, and the shapes of the protrusions and grooves are not limited to those of this embodiment.

  As shown in FIGS. 1 and 2, the winding 15 is formed by winding a predetermined number of turns around the bobbin 2 using a conductor (a round wire or a flat wire) in which a conductive wire is coated with an insulating coating. For example, Cu, Au, Ag, Fe, Pt, Sn, Ni, Pb, Al, Co, or an alloy thereof can be used as the material of the conductor 10 of the winding, and Cu is preferably used. The both ends of the conductor constituting the winding 15 have a predetermined dimension, the insulation coating is removed, and a terminal is formed to form the winding 15.

  Next, the manufacturing method of the winding coil of this invention is demonstrated. As shown in FIG. 7, first, the bobbin bodies 2a, 2b, 2c, 2d are inserted through the linear shaft core 8 of the automatic winding machine. At this time, a spherical ball (ball) provided with a spring mechanism is used as an embedding stopper 9 on the linear shaft core 8 of the automatic winding machine located at the end of the hollow portion of the bobbin body 2d, and the bobbin bodies 2a and 2b. , 2c, 2d are fixed.

  Next, as shown in FIG. 8, after the end of the conducting wire is wound around the upper portion of the pin terminal 5 provided on the bobbin body 2a and temporarily fixed, the automatic winding is rotated and the predetermined number of turns is set to the bobbin winding. Wrap in the frame.

  Further, when winding the bobbin body 2b, the winding end of the bobbin body 2b is started after the winding end of the bobbin body 2a is hooked on the conductor groove 6 (FIG. 5) provided in the bobbin body 2b. At this time, the bobbin body 2a is routed to the bobbin body 2b with a certain amount of margin 14 to cross the conductor.

  Next, the bobbin bodies 2c and 2d are wound in the same manner as the bobbin bodies 2a and 2b, and pin terminals are provided on the bobbin body 2d with conductor ends after completion of the predetermined winding of the bobbin body 2d. 5 is wound and temporarily fixed, and then the fixed portion of the pin terminal 5 of the bobbin bodies 2a and 2d is fixedly connected to the pin terminal 5 and the conductor 10 with solder or the like to complete the coil. To do.

  Next, as shown in FIG. 9, a plate-shaped core piece is inserted into the hollow portion of the bobbin body 2a after the winding is completed, and another core piece is inserted into the L-shape in the vicinity of the tip and inserted into the bobbin body 2b. Further, another core piece is inserted into the bobbin body 2c at the tip of the core piece, and another core piece is inserted into the bobbin body 2d to complete the coil. At this time, each bobbin body 2a, 2b, 2c, 2d is fitted to one convex protrusion 3 (FIG. 5) at the opposite side and the other concave groove 4 (FIG. 5). Can be fixed.

  Next, a magnetic material containing a plurality of types of soft magnetic materials and non-magnetic resin is applied to the joints 11 (FIG. 3) of the core pieces of the coil, and is heated and cured to complete a closed magnetic circuit coil in which the core pieces are integrated. .

  In the present invention, the plate-shaped core is made of a magnetic body containing a plurality of types of soft magnetic materials and nonmagnetic resins, but other soft magnetic materials (for example, Fe, Fe—Ni—Mo (supermalloy), Fe—Al—Si) are used. (Sendust), Fe-Co, Fe-Si, Fe-P, etc.) may be used.

  In the present invention, the magnetic material containing the plurality of types of soft magnetic materials and non-magnetic resin is applied to the joint portion 11 of each core piece and cured by heating. However, other adhesives (epoxy type or acrylic type) are used. Or phenolic) or varnish impregnation.

  Further, when the core pieces are fixed more firmly, a holder such as a metal fitting may be used.

  In the above example, the winding conductor 10 is connected to the pin terminal 5 provided on the bobbin 2 shown in FIG. 1 to form an external connection terminal. However, as shown in FIG. 2 may be used as the external connection terminal 23.

(Embodiment 2)
Another embodiment of the present invention will be described. FIG. 11 is a plan view of a winding coil according to the second embodiment of the present invention. FIG. 12 is a plan view showing a joined state of the core in the second embodiment of the present invention.

  The core 12 in FIG. 11 is a deformed trapezoid in which each core piece is cut out from a corner to a triangle, and as shown in FIG. The core volume can be reduced by joining the surface of the piece and making it rectangular.

1 is an external perspective view of a wound coil according to a first embodiment of the present invention. The top view of the winding coil in the 1st Embodiment of this invention. The top view which shows the joining state of the core in the 1st Embodiment of this invention. The flowchart which showed the manufacturing process of the core in the 1st Embodiment of this invention. The expanded view explaining the bobbin in the 1st Embodiment of this invention. 5 (a) is a plan view, FIG. 5 (b) is a left side view, FIG. 5 (c) is a front view, FIG. 5 (d) is a right side view, and FIG. 5 (e) is a bottom view. Figure. The top view which shows the fitting state of the uneven | corrugated | grooved part of the bobbin in the 1st Embodiment of this invention. The perspective view which shows the state which sets the axial center of the automatic winding machine in the 1st Embodiment of this invention to a bobbin. The perspective view explaining the method to wind a conductor to the bobbin in the automatic winding machine in the 1st Embodiment of this invention. The perspective view which shows the state after the assembly of the bobbin which wound the conductor in the 1st Embodiment of this invention. The perspective view which shows the other example of the external connection terminal of the winding coil in the 1st Embodiment of this invention. The top view of the coil | winding coil in the 2nd Embodiment of this invention. The top view which shows the joining state of the core in the 2nd Embodiment of this invention. The top view which shows the structure of the conventional toroidal coil. The top view which shows the structure of the toroidal coil of the other conventional example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Core 2 Bobbin 2a, 2b, 2c, 2d Bobbin body 3 Convex protrusion 4 Concave groove 5 Pin terminal 6 Conductor groove 7 Hollow part 8 Shaft core 9 Stopper 10 Conductor 11 Joint part 12 Core 13 Conductor end
14 Margin 15 (of the drawn conductor) Winding 23 External connection terminal 101 Tubular coil 102 Ring core 111 Toroidal coil 112 (Deformation) Bobbin 112a Long side portion 112b Short side portion 113 Ring core 114 Conductor

Claims (3)

  Four rods or plate-shaped core pieces of the same shape made of a magnetic material, and hooks formed at both ends of the core, and fitted to the end face of one of the hooks and the other hook. Four bobbin bodies having the same shape provided with a portion, each of the core pieces being inserted into the core, and the end face on the short side of the core piece being the long side of the core piece different from the core piece The core piece is joined to the end face of the core piece, and the same material as the magnetic material is applied to the joint part of the core piece to form a closed magnetic circuit core, and the bobbin body is wound, and the locking part is fitted. In combination, the core piece and the bobbin body are combined in a rectangular shape.   2. The core piece according to claim 1, wherein a magnetic material obtained by mixing a plurality of types of soft magnetic materials and resin is compression molded or cast into a box-shaped mold, and then cured and molded into a rod shape or a plate shape. Winding coil.   A method for manufacturing a wound coil in which four core pieces having the same shape and four bobbin bodies having the same shape are combined in a rectangular shape, and a magnetic material obtained by mixing a plurality of types of soft magnetic materials and a resin is compacted. Alternatively, after casting into a box-shaped mold, the core piece is molded into a rod-like or plate-like shape, and ridges are formed at both ends of the bobbin core, and the end surface of one of the ridges The other hook is provided with a locking portion that is fitted to each other, and after winding the winding core, the step of fitting the locking portion, the core piece is inserted into the winding core, and the core piece The end face on the short side of the core piece is joined to the end face of the end part on the long side of the core piece different from the core piece, and the same material as the magnetic material is applied to the joint part of the core piece to form a closed magnetic circuit core The manufacturing method of the winding coil characterized by including the process to do.

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