JP2009123825A - Coil device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To miniaturize and make compact an entire coil device by extending a creepage distance between coils, and to reduce the costs of components and manufacture. <P>SOLUTION: In a first case member 3p, a first barrier plate section 6 is provided which is integrally formed at one edge of a baseplate section 5 and opposes one edge of a pair of coils 2a, 2b, and has a pair of bobbin insertion holes 7a, 7b. In a second case member 3q, a second barrier plate section 9 is provided which integrally forms a pair of coil bobbin sections 8a, 8b and the rear edges of the coil bobbin sections 8a, 8b and opposes the other edge of the pair of coils 2a, 2b. Further, a partition barrier plate section 10 for partitioning the pair of coils 2a, 2b is integrally formed at one of the first and second case members 3p, 3q, and a partition insertion hole 11 to which a contact section 10s of the partition barrier plate section 10 is inserted is formed at the other. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a coil device having a pair of coils attached to an AC power source and a power line connecting between devices using the AC power source.

  Conventionally, there is known a noise filter that is attached to a power supply line that connects between an AC power supply and a device that uses the AC power supply to remove noise of the power supply line. A coil device is provided in which a coil is housed in a case.

For example, Patent Document 1 discloses a noise filter that is configured by a capacitor connected between lines of a common mode choke coil and a capacitor connected between each line and the ground, and is inserted between an AC power supply and an electronic device. In addition, there is a metal board wiring board that has a thin insulating layer with high thermal conductivity on the metal plate of a good thermal conductor, and a conductive foil printed wiring pattern on this insulating layer, and there are holes or screws to be screwed on the top. The input terminal, the output terminal and the ground terminal having a part to be soldered on the bottom surface, the capacitor connected between the input terminals, the capacitor connected between the output terminals and the ground terminal, and each output terminal are connected. Capacitor electrodes that can be mounted on a printed wiring pattern and placed on a printed wiring pattern and can be self-supported and soldered. There is disclosed a noise filter that is fixed to a case that holds a cable and that is connected to an electric wire constituting a common mode choke coil and that is provided with a common mode choke coil electrode that can be mounted on a printed wiring pattern and soldered. The noise filter is provided with a common mode choke coil, that is, a coil device, placed in a case.
JP 2001-217668 A

  However, the conventional coil device provided in the above-described noise filter has the following problems.

  First, since a relatively high voltage is normally applied to a coil device attached to a power supply line connected to an AC power supply, it is necessary to provide electrical insulation based on regulations, between the coil and the core or The distance between the lines (creeping distance) is more than a certain distance. Accordingly, it is easy to increase the size of the case for accommodating the coil, and further the entire coil device.

  Secondly, the number of parts and the number of manufacturing steps are increased due to the support structure for supporting the coil and the lead-out structure of the coil lead from the case.

  The object of the present invention is to provide a coil device that solves such problems in the background art.

  In order to solve the above-described problems, the present invention configures a coil device 1 having a pair of coils 2a and 2b attached to power lines Lc and Lc that connect between an AC power source and a device M that uses the AC power source. The coil case 3 is configured by assembling the first case member 3p and the second case member 3q, and at least the lead portions 2as, 2at, 2bs, and 2bt of the pair of coils 2a and 2b are led out to the first case member 3p. A base plate portion 5 having lead-out holes 4... And a tip end side of a pair of coil bobbin portions 8 a and 8 b that are integrally formed on one end side of the base plate portion 5, face one end of the pair of coils 2 a and 2 b, and form a cylindrical shape. A first barrier plate portion 6 having a pair of bobbin insertion holes 7a and 7b into which 8ai and 8bi can be inserted is provided. At least a pair of coil bobbin portions 8a and 8b and rear ends of the coil bobbin portions 8a and 8b are integrally formed, and a second barrier plate portion 9 is provided opposite to the other ends of the pair of coils 2a and 2b. A partition barrier plate portion 10 that partitions the pair of coils 2a and 2b is integrally formed on one case member 3p or the second case member 3q, and a partition barrier is formed on the other of the first case member 3p or the second case member 3q. A partition insertion hole 11 into which the contact portion 10s of the plate portion 10 is inserted is formed.

  In this case, according to a preferred aspect of the invention, a pair of left and right side plate portions 15a and 15b covering the sides of the coils 2a and 2b can be integrally formed on the left and right ends of the base plate portion 5, respectively. On the other hand, the coil device 1 can be provided with a pair of core portions 16p and 16q having a U-shape inserted from both ends with respect to the coil bobbin portions 8a and 8b. Moreover, the pair of coils 2a and 2b can use the longitudinal winding coil which wound the flat conducting wire Ws. The pair of coils 2a and 2b can be used as a common mode coil constituting a noise filter F that removes noise from the power supply lines Lc and Lc, and constitutes a noise filter that removes noise from the power supply lines Lc and Lc. It can also be used as a normal mode coil connected in series or connected in parallel.

  The coil device 1 according to the present invention having such a configuration has the following remarkable effects.

  (1) The rear ends of the coil bobbin portions 8a and 8b are formed integrally with the second case member 3q, and the tip ends 8ai and 8bi of the coil bobbin portions 8a and 8b are inserted into the bobbin insertion holes 7a and 7b of the first case member 3p. In addition, a partition barrier plate portion 10 that partitions the pair of coils 2a and 2b is integrally formed on one of the first case member 3p and the second case member 3q, and the contact portion 10s of the partition barrier plate portion 10 is formed on the other side. Since it is inserted, even if the apparent distance between the coils 2a and 2b or the like is shortened, a substantial distance (creeping distance) when being attached to the power supply lines Lc and Lc to which a relatively high voltage is applied. Can be lengthened. Therefore, necessary insulation can be ensured, and the coil case 3 and further the coil device 1 as a whole can be reduced in size and size.

  (2) The coil case 3 includes a first case member 3p having lead-out holes 4 for leading out the lead portions 2as ... of the coils 2a, 2b, and a second case member 3q integrally having a pair of coil bobbin portions 8a, 8b. Therefore, basically, the two parts of the first case member 3p and the second case member 3q are sufficient. Therefore, since the number of parts and the number of manufacturing steps can be reduced, it is possible to realize cost reduction associated with parts and manufacturing in the entire coil device 1.

  (3) If a pair of left and right side plate portions 15a and 15b that cover the sides of the coils 2a and 2b are integrally formed on the left and right edges of the base plate portion 5 according to a preferred embodiment, without increasing the number of parts, A coil housing portion surrounding the coil case 3 together with the first barrier plate portion 6 and the second barrier plate portion 9 can be easily formed.

  (4) If the coil device 1 is provided with a pair of core portions 16p and 16q having U-shapes to be inserted from both ends with respect to the coil bobbin portions 8a and 8b according to a preferred embodiment, the first barrier plate portion 6 In addition, the structure of the second barrier plate portion 9 and the coil bobbin portions 8a and 8b can be easily assembled, and in particular, the insertion structure of the tip side 8ai and 8bi of the coil bobbin portions 8a and 8b with respect to the first barrier plate portion 6 Thus, the substantial creepage distance between the coils 2a and 2b and the core portions 16p and 16q can be increased.

  (5) According to a preferred embodiment, if a vertically wound coil in which a flat conducting wire Ws is wound is used for the pair of coils 2a and 2b, a lead-out hole formed in the base plate portion 5 without using a printed circuit board or a separate electrode. .. Can be easily provided by simply inserting the lead portions 2as.

  (6) According to a preferred aspect, the pair of coils 2a and 2b is a common mode coil constituting a noise filter F that removes noise from the power supply lines Lc and Lc, or a noise filter that removes noise from the power supply lines Lc and Lc. Can be used as a normal mode coil connected in series or in parallel, which can contribute to a reduction in size and cost of the noise filter.

  Next, the best embodiment according to the present invention will be given and described in detail with reference to the drawings.

  First, components used in the coil device 1 according to the present embodiment will be described with reference to FIGS.

  As shown in FIG. 3, the coil device 1 includes a coil case 3, a pair of coils 2a and 2b, and a pair of core portions 16p and 16q, each of which is constituted by a first case member 3p and a second case member 3q.

  In the first case member 3p, the base plate portion 5, the first barrier plate portion 6, the partition barrier plate portion 10, and the pair of left and right side plate portions 15a and 15b are integrally formed of an insulating material such as plastic. The base plate portion 5 is formed in a rectangular shape, and four lead-out holes 4 penetrating vertically are provided in the plate surface. A pair of coils 2a, 2b are arranged side by side on the upper surface of the base plate portion 5, and the lead portions 2as, 2at, 2bs, 2bt of the coils 2a, 2b are inserted from above into the respective lead-out holes 4 ... Can be projected (derived). The first barrier plate portion 6 stands upright from one end side of the base plate portion 5 at a right angle, and a pair of left and right bobbin insertion holes 7a and 7b are provided in the plate surface, and a core cover portion is provided on the outer surface. 21 is formed integrally. In the bobbin insertion holes 7a and 7b, distal end sides 8ai and 8bi of a pair of coil bobbin portions 8a and 8b having a cylindrical shape to be described later can be inserted (fitted), and the inserted (fitted) coil bobbin portions 8a and 8b On the other hand, a core portion 16p having a U-shape described later can be inserted from the outside. Therefore, the core cover part 21 can cover the left and right sides and the upper side of the inserted core part 16p. Further, the partition barrier plate portion 10 stands vertically upward from the center position in the left-right direction of the base plate portion 5, and one end side in the front-rear direction is made continuous with the inner surface of the first barrier plate portion 6. A protruding contact portion 10 s including at least the center position in the vertical direction is provided on the other end side in the front-rear direction of the partition barrier plate portion 10. The contact portion 10s can be inserted into a partition insertion hole 11 provided in the second barrier plate portion 9 described later. The partition barrier plate portion 10 provides a pair of coil housing portions Sa and Sb on the left and right sides of the partition barrier plate portion 10. On the other hand, the pair of left and right side plate portions 15 a and 15 b stand upright at right angles from the left and right end sides of the base plate portion 5, and one end side in the front-rear direction is continued to the left and right end sides of the first barrier plate portion 6. In this way, if the pair of left and right side plate portions 15a and 15b covering the sides of the coils 2a and 2b are integrally formed on the left and right edges of the base plate portion 5, the first barrier plate without increasing the number of parts. There exists an advantage which can form easily the coil accommodating part which surrounds the circumference | surroundings of the coil case 3 with the part 6 and the 2nd barrier plate part 9. FIG. The side plate portions 15 a and 15 b are selected so that the length in the front-rear direction is slightly shorter than the length in the front-rear direction of the base plate portion 5. It can be placed on the top surface.

  In the second case member 3q, the second barrier plate portion 9 and the pair of left and right coil bobbin portions 8a and 8b are integrally formed of an insulating material such as plastic. The outer shape of the second barrier plate portion 9 is the same as that of the first barrier plate portion 6, and the rear ends of the pair of coil bobbin portions 8a and 8b are integrally formed on the inner surface and protruded at a right angle. Core insertion holes 9a and 9b communicating with the inside of the coil bobbin portions 8a and 8b are formed in the plate surface of the second barrier plate portion 9, and the core cover portion 22 is integrally formed on the outer surface. A core portion 16q having a U-shape, which will be described later, can be inserted into the core insertion holes 9a and 9b from the outside. Therefore, the core cover part 22 can cover the left and right sides and the upper side of the inserted core part 16q.

  As the pair of coils 2a and 2b, a longitudinal coil in which a flat conducting wire Ws having a rectangular (rectangular) cross section is wound is used. Since the pair of coils 2a and 2b can be configured identically, two identical coils 2a... Are prepared, and one is used as the coil 2a and the other is used as the coil 2b. As shown in FIG. 2, one coil 2a extends at both ends downward, and uses one end side as a lead portion 2as and the other end side as a lead portion 2at. Similarly, one end side of the other coil 2b is used as a lead portion 2bs, and the other end side is used as a lead portion 2bt. As described above, when the longitudinal coil wound with the rectangular conducting wire Ws is used, the lead portion 2as is simply inserted into the lead-out hole 4 formed in the base plate portion 5 without using a printed circuit board or a separate electrode. There is an advantage that an external connection lead can be easily provided.

  The pair of core portions 16p and 16q are each formed in a U shape by a magnetic material such as ferrite. Since the pair of core portions 16p and 16q can be configured identically, two identical core portions 16p... Are prepared, and one is used as the core portion 16p and the other is used as the core portion 16q. Each core part 16p, 16q can be inserted from both ends with respect to each coil bobbin part 8a, 8b. Even when such a pair of core portions 16p and 16q is used, the first barrier plate portion 6 and the second barrier plate portion 9 and the coil bobbin portions 8a and 8b can be easily assembled. In addition, in particular, there is an advantage that the substantial creepage distance between the coils 2a, 2b and the core portions 16p, 16q can be increased by the insertion structure of the tip sides 8ai, 8bi of the coil bobbin portions 8a, 8b with respect to the first barrier plate portion 6. In addition, some core parts 16p and 16q which protrude outside from the 1st barrier plate part 6 and the 2nd barrier plate part 9 are each covered with the core cover parts 21 and 22, and are protected externally.

  Next, a method for assembling the coil device 1 according to the present embodiment will be described with reference to FIGS.

  First, the coils 2a and 2b are assembled to the first case member 3p. In this case, the coils 2a and 2b are accommodated in the coil accommodating portions Sa and Sb of the first case member 3p, respectively, and the lead portions 2as, 2at, 2bs, and 2bt of the coils 2a and 2b are respectively accommodated in the corresponding lead-out holes 4. Insert. Thereby, each lead part 2as, 2at, 2bs, 2bt protrudes (leads out) below the base plate part 5, and becomes a connection lead that is directly connected to an external substrate or the like.

  Next, the second case member 3q is assembled to the first case member 3p. In this case, the second case member 3q is assembled to the first case member 3p from the direction of the arrow shown in FIG. 3, and at this time, the coil bobbin portions 8a and 8b in the second case member 3q are connected to the first case member. The coil bobbins 8a and 8b are inserted into the bobbin insertion holes 7a and 7b of the first barrier plate portion 6 in the first case member 3p. The contact portion 10s of the partition barrier plate portion 10 in the first case member 3p is inserted (fitted) into the partition insertion hole 11 of the second barrier plate portion 9 in the second case member 3q.

  As a result, as shown in a partially extracted enlarged view in FIG. 4, the tip ends 8ai and 8bi of the coil bobbin portions 8a and 8b and the bobbin insertion holes 7a and 7b are fitted with no backlash, and the tips of the coil bobbin portions 8a and 8b are fitted. The front end surfaces of the sides 8 ai and 8 bi substantially coincide with the outer surface of the first barrier plate portion 6. Further, the contact portion 10 s and the partition insertion hole 11 are fitted with no backlash, and the front end surface of the contact portion 10 s substantially coincides with the outer surface of the second barrier plate portion 9. Therefore, in the state where the first case member 3p and the second case member 3q are assembled, the second case member 3q is fixed while being positioned in the left-right direction, the front-rear direction, and the up-down direction with respect to the first case member 3p. Is done. The creeping distance between the coils 2a, 2b and the core portions 16p, 16q can be increased by such an insertion structure (fitting structure) between the tip ends 8ai, 8bi of the coil bobbin portions 8a, 8b and the first barrier plate portion 6. In addition, the creeping distance between the coils 2a and 2b can be increased by the insertion structure (fitting structure) of the contact portion 10s and the second barrier plate portion 9 provided in the partition barrier plate portion 10.

  Next, the core parts 16p and 16q are assembled. In this case, the one core portion 16p is inserted into the coil bobbin portions 8a and 8b from the outside of the first barrier plate portion 6, that is, the coil bobbin portion facing the outer surface of the first barrier plate portion 6 from the arrow direction shown in FIG. It inserts in the end surface opening of the front end side 8ai, 8bi in 8a, 8b. The other core portion 16q is inserted into the coil bobbin portions 8a and 8b from the outside of the second barrier plate portion 9, that is, the core insertion hole 9a provided in the second barrier plate portion 9 from the arrow direction shown in FIG. , 9b and inserted into the coil bobbin portions 8a, 8b. As a result, the ends of the core portions 16p and 16q are brought into contact with each other, thereby forming a closed magnetic path having a rectangular shape.

  When the above assembly is completed, taping 31 is applied along the outer peripheral surface as shown in FIG. In this case, as shown in FIG. 2, a fixing tape T having a width substantially matching the vertical width of the core cover portion 21 (22) is prepared, and this tape T is used as the core cover portions 21 and 22 and the side plate. It winds along the outer peripheral surface containing the parts 15a and 15b. By this taping 31, the first case member 3p, the second case member 3q, and the core portions 16p and 16q are fixed, and the target coil device 1 shown in FIG. 7 can be obtained.

  Next, a specific use example of the coil device 1 according to the present embodiment will be described with reference to FIG.

  As shown in FIG. 8, the coil device 1 is particularly attached to power lines Lc and Lc that connect between an AC power source and a device M that uses the AC power source, and a noise filter F that removes noise from the power lines Lc and Lc. Can be used as FIG. 8 shows a noise filter F using a pair of coils 2a and 2b as a common mode coil. The coil device 1 shown in FIG. 8 forms a noise filter F in combination with capacitors 42, 43, 44, 45 and choke coil 46, which are other components. The example device M shows a switching regulator 47 and a load (industrial robot, air conditioner, etc.) 48 connected to the switching regulator 47. Reference numeral 41 denotes a power plug connected to an AC power source. Although FIG. 8 shows the case where the pair of coils 2a and 2b are used as a common mode coil, the pair of coils 2a and 2b can also be used as a normal mode coil connected in series or in parallel. By using the coil device 1 for such a noise filter, there is an advantage that it is possible to contribute to the downsizing and cost reduction of the noise filter.

  Therefore, according to the coil device 1 according to the present embodiment, the rear ends of the coil bobbin portions 8a and 8b are integrally formed on the second case member 3q, and the front end sides 8ai and 8bi of the coil bobbin portions 8a and 8b are connected to the second case member 3q. A partition barrier plate portion 10 for partitioning the pair of coils 2a, 2b is formed integrally with one of the first case member 3p or the second case member 3q, while being inserted into the bobbin insertion holes 7a, 7b of the case member 3p, and On the other hand, since the contact portion 10s of the partition barrier plate portion 10 is inserted, even if the apparent distance between the coils 2a and 2b is shortened, the power supply line Lc, to which a relatively high voltage is applied, The substantial distance (creeping distance) at the time of attaching to Lc can be increased. Therefore, necessary insulation can be ensured, and the coil case 3 and further the coil device 1 as a whole can be reduced in size and size. The coil case 3 includes a first case member 3p having lead-out holes 4 for leading out the lead portions 2as ... of the coils 2a, 2b, and a second case member 3q having a pair of coil bobbin portions 8a, 8b integrally. Since it is assembled and configured, two parts of the first case member 3p and the second case member 3q are basically sufficient. Therefore, since the number of parts and the number of manufacturing steps can be reduced, it is possible to realize cost reduction associated with parts and manufacturing in the entire coil device 1.

  Although the best embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the scope of the present invention is not deviated from the gist of the present invention in the detailed configuration, shape, material, quantity, and the like. It can be changed, added, or deleted arbitrarily.

  For example, the pair of coils 2a and 2b does not mean two as the number. Therefore, it may be three coils 2a, 2b, 2c or four or more coils 2a, 2b... In the case of three coils 2a, 2b, 2c, a pair of coils 2a, 2b and a pair of coils 2b. , 2c. Further, it is not always necessary to provide a pair of left and right side plate portions 15a, 15b, a pair of core portions 16p, 16q, etc., which are integrally formed on the left and right ends of the base plate portion 5 and cover the sides of the coils 2a, 2b. On the other hand, as the pair of coils 2a and 2b, it is desirable to use a longitudinally wound coil in which a flat conducting wire Ws is wound, but this does not exclude the use of a general round conducting wire. In addition, although the coil apparatus 1 which concerns on this invention illustrated the noise filter attached to the power supply lines Lc and Lc as a usage example (application), the power supply which connects between the apparatus M which uses AC power supply and this AC power supply in addition to this It can be similarly used for various coil devices 1 that can be attached to the lines Lc, Lc, for example, a power factor improving coil, a smoothing coil, a step-up / step-down coil, a transformer, and the like.

Sectional plan view of a coil device according to the best embodiment of the present invention, A partial cross-sectional front view of the coil device, Exploded plan view of components used in the coil device; A partial cross-sectional plan view including a partial enlarged view of the coil case used in the coil device; A partial cross-sectional side view of a coil bobbin portion of a coil case used in the coil device, The partial cross section side view in the partition barrier plate part of the coil case used for the coil device, A plan view of the coil device, Electric circuit diagram showing an example of use of the coil device;

Explanation of symbols

  1: coil device, 2a: coil, 2b: coil, 2as: lead portion, 2at: lead portion, 2bs: lead portion, 2bt: lead portion, 3: coil case, 3p: first case member, 3q: second case Member: 4 ...: Lead-out hole, 5: Base plate part, 6: First barrier plate part, 7a: Bobbin insertion hole, 7b: Bobbin insertion hole, 8a: Coil bobbin part, 8b: Coil bobbin part, 8ai: Tip side of coil bobbin part 8bi: tip side of coil bobbin portion, 9: second barrier plate portion, 10: partition barrier plate portion, 10s: contact portion, 11: partition insertion hole, 15a: side plate portion, 15b: side plate portion, 16p: Core part, 16q: Core part, M: Device, Lc: Power supply line, Ws: Flat conductor, F: Noise filter

Claims (6)

  A coil device having a pair of coils attached to an AC power supply and a power supply line connecting between devices using the AC power supply, comprising a coil case configured by assembling a first case member and a second case member, A base plate portion having a lead-out hole for leading at least the lead portions of the pair of coils in the case member, and a pair of cylindrical members integrally formed on one end side of the base plate portion and facing one end of the pair of coils A first barrier plate portion having a pair of bobbin insertion holes into which the distal end side of the coil bobbin portion can be inserted, and at least the pair of coil bobbin portions and the rear end of the coil bobbin portion are integrally formed on the second case member. A second barrier plate portion facing the other end of the pair of coils, and further, the first case member or the A partition barrier plate portion for partitioning the pair of coils is integrally formed on one of the two case members, and a contact portion of the partition barrier plate portion is inserted on the other of the first case member or the second case member. A coil device comprising a partition insertion hole.   The coil device according to claim 1, wherein a pair of left and right side plate portions covering the sides of the coil are integrally formed on the left and right end sides of the base plate portion.   The coil device according to claim 1, further comprising a pair of core portions having a U-shape that is inserted into both ends of the coil bobbin portion.   The coil device according to claim 1 or 3, wherein the pair of coils is a vertically wound coil in which a flat wire is wound.   5. The coil device according to claim 1, wherein the pair of coils are used as a common mode coil constituting a noise filter for removing noise of the power supply line.   5. The coil device according to claim 1, wherein the pair of coils are used as a normal mode coil connected in series or in parallel to constitute a noise filter for removing noise of the power supply line.

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