JP2011103421A - Inductor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inductor which can prevent direct contact between a core and a case, and be manufactured at low cost. <P>SOLUTION: The inductor has a measure-shaped case, a core accommodated in the case, a winding wound around a part of the core, and a fixing member fixed to the case and abutting on the core to hold the core so that the core may not abut on the bottom of the case. The fixing member is configured by integrally forming: a first holding part as a plate spring, which abuts on the first surface of the core at a position close to an opening of the case and urges the core to the bottom of the case; a second holding part as a plate spring, which abuts on the second surface of the core at a position close to an opening of the case and urges the core to the bottom of the case; and a third holding part as a plate spring, which abuts on the side surface of the core at a position close to an opening of the case and urges the core to the inner side surface of the case. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an inductor formed by housing a core around which a conducting wire is wound in a case.

  As a reactor used in an electric circuit, an inductor as shown in Patent Document 1 is used. FIG. 6 shows a perspective view of an inductor (reactor) having a conventional configuration disclosed in Patent Document 1. In FIG.

JP 2009-26952 A

  As shown in FIG. 6, in the reactor 101 having the conventional configuration, a substantially O-shaped core 120 and a pair of windings that are wound around the core 120 are formed in a recess 111 a formed on the bottom surface 111 of the case 110. The line 130 is accommodated.

  In order to hold the core 120 in the recess 111 a of the case 110, four sets of fixing metal fittings 141 are used. Each of these fixing fittings 141 is a fitting integrated with the core 120 by a mold resin. The distal ends of the four sets of fixing fittings extend radially from the four corners of the core 120, respectively. A through hole (not shown) is formed at the distal end of the fixing metal 141. The core 120 attaches the fixing metal 141 to the case 110 by screwing the fixing metal 141 through the bolt 142 through the through hole of the fixing metal 141. And is fixed in the recess 111 a of the case 110.

  The fixing metal 141 floats the core 120 from the recess 111 a of the case 110 so that the core 120 does not contact the case 110. Thereby, direct contact between the case 110 and the core 120 is prevented. In the configuration of Patent Document 1, since the direct contact between the case 110 and the core 120 is prevented as described above, the vibration of the core 120 that can be generated when a current is passed through the winding is transmitted to the case 110. And noise generation due to vibration of the case 110 is prevented.

  In the configuration in which the core 120 and the fixture 141 are integrated with a resin mold as in Patent Document 1, there is a problem that a mold cost is required. In addition, in order to enable the fixing bracket 141 to be screwed to the case 110, the interval between the through holes of the fixing bracket 141 and the interval between the female screws for the bolt 142 formed in the case 110 are highly accurate. Must match. That is, when the core 120 and the fixture 141 are integrally formed, a jig is required for positioning the fixture 141 with respect to the core 120 with high accuracy. For these reasons, the manufacturing cost of the reactor 101 of Patent Document 1 is large.

  The present invention has been made to solve the above problems. That is, an object of the present invention is to provide an inductor with a low manufacturing cost that can prevent direct contact between a core and a case.

  In order to achieve the above object, an inductor according to the present invention includes a bowl-shaped case, a core housed in the case, a winding wound around a portion of the core, and a case fixed to the core. And a fixing member that holds the core so as not to contact the bottom surface of the case, and the fixing member contacts the first surface of the core that is proximal to the opening of the case and holds the core. A first holding portion that is a leaf spring that urges toward the bottom surface of the case, and a second surface of the core that is proximal to the bottom surface of the case so that the core faces the opening of the case A second holding portion that is a leaf spring that urges and a third holding portion that is a leaf spring that abuts against the side surface of the core and urges the core toward the inner side surface of the case are integrally formed. It has been done.

  In the configuration of the present invention, the first, second, and third holding portions, which are leaf springs, contact the core and urge the core as described above, so that the positioning of the fixing member and the core is strictly limited. It is not necessary to carry out positioning, and a jig for positioning is not required. The core and the winding can be held in the case while the core is levitated from the case by a simple process of housing the core held by the fixing member in the case and fixing the fixing member to the case. For this reason, according to the structure of this invention, the inductor with the low manufacturing cost which can prevent the direct contact of a core and a case is implement | achieved.

  It is preferable that the dimension in the width direction of the first holding portion is configured to become smaller from the proximal end portion to the distal end portion of the first holding portion. Similarly, it is preferable that the width direction dimension of the second holding portion is configured to become smaller from the base end portion toward the tip end portion of the second holding portion.

  With such a configuration, it is possible to adjust the spring constant of the tip of the first holding part or the second holding part to a desired value. Further, it is possible to disperse the bending stress at the tips of the first holding part and the second holding part and prevent stress concentration.

  In addition, a contact portion that contacts the core in the first holding portion and a contact portion that contacts the core in the second holding portion are arranged side by side in a direction from the opening of the case toward the bottom surface. A configuration is preferable.

  With such a configuration, the stress inside the core due to the load applied to the core from the first and second holding portions is mainly compressive stress so that almost no shearing stress or moment to rotate the core is applied. Become. As a result, the core is stably held.

  The third holding portion is disposed between the side surface of the core and the inner side surface of the case and has a plate-like base end portion extending in a direction along the inner side surface of the case, and the case of the base end portion It is good also as a structure provided with the front-end | tip part which bends in U shape from the end of the bottom face side, and contact | abuts to the side surface of this core.

  Furthermore, the first holding part has a tip part that is bent in a substantially L shape from the plate-like part including the base end part of the third holding part and extends in the direction toward the first surface of the core, A part of the part may be in contact with the first surface of the core and bias the core.

  Further, the plate-like portion including the base end portion of the third holding portion is divided into three portions by two slits extending from the opening of the case toward the bottom surface, and the three pieces of the divided plate-like portions are separated. Among the portions, the third holding portion is formed at two portions at both ends, and the second holding portion is a portion sandwiched between the third holding portions among the three portions of the divided plate-like portion. Having a tip portion that is bent in a substantially L shape from the tip and extends in a direction toward the second surface of the core, and a portion of the tip portion abuts on the second surface of the core and biases the core It is good.

  Moreover, it is good also as a structure which has two or more sets of fixing members.

  As described above, according to the present invention, an inductor with a low manufacturing cost that can prevent direct contact between the core and the case is realized.

FIG. 1 is a perspective view of a reactor according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the reactor according to the embodiment of the present invention. FIG. 3 is an exploded view of the core and winding according to the embodiment of the present invention. FIG. 4 is an exploded view of the reactor according to the embodiment of the present invention. 5 (a), (b), (c), (d) and (e) are respectively a front view, a left side view, a right side view, a top view and a first fixing member according to the embodiment of the present invention. It is a bottom view. FIG. 6 is a perspective view of a reactor according to an embodiment having a conventional configuration.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view of a reactor as an inductor according to the present embodiment. FIG. 2 is a side sectional view of the reactor of the present embodiment. As shown in FIG. 1, the reactor 1 of the present embodiment is one in which two sets of windings 31 and 32 are wound around a substantially O-shaped core 20 and accommodated in a bowl-shaped case 10. One ends (not shown) of the windings 31 and 32 are joined, and the windings 31 and 32 form a circuit connected in series as a whole. Further, the reactor 1 is connected to an electric circuit through the other ends of the windings 31 and 32. The windings 31 and 32 are accommodated in the case 10 without jumping out from the upper end 15 of the case 10.

  In the following description, the vertical direction, the width direction, and the depth direction are defined based on the state in which the reactor 1 is arranged as shown in FIG. That is, in FIG. 2, the side where the opening O of the case 10 is located is the upper side in the vertical direction. In FIG. 2, the right side when the opening of the case 10 is turned up is defined as the right side in the width direction of the reactor 1. The depth direction is a direction perpendicular to both the vertical direction and the width direction, that is, the direction from the front side to the back side of the paper surface in FIG. 2, the front side of the paper surface in FIG. Become.

  The assembly procedure of the reactor 1 of this embodiment is demonstrated below. FIG. 3 is an exploded view of the core 20 and the windings 31 and 32 of the present embodiment. As shown in FIG. 3, the core 20 includes a pair of U-shaped cores 21 arranged in the width direction and a pair of I-shaped cores disposed between the arms 21 a on the depth direction side of the pair of U-shaped cores 21. 22a, a pair of I-shaped cores 22b disposed between the arms 21b on the near side in the depth direction of the pair of U-shaped cores 21, between the arms 21a of the U-shaped core 21 and the I-shaped cores 22a, and a pair of I-shaped cores 22a. The gap plate 23a is disposed between the arms 21b and the I-shaped core 22b of the U-shaped core 21 and between the pair of I-shaped cores 22b.

  The arm 21a and the I-shaped core 22a of the U-shaped core 21 and the gap plate 23a are joined by an adhesive. Similarly, the arm 21b and the I-shaped core 22b of the U-shaped core 21 and the gap plate 23b are also joined with an adhesive. One U-shaped core 21, a pair of I-shaped cores 22a, a pair of I-shaped cores 22b, and gap plates 23a and 23b are joined with an adhesive to form a U-shaped core. The windings 32 and 32 are passed through the O-shaped core 20 by passing the winding 32 through the core 22a and the I-shaped core 22b, respectively, and then bonding the other U-shaped core 21 to the gap plates 23a and 23b. The formed block is formed.

  Next, a block including the core 20 and the windings 31 and 32 is accommodated in the case 10. FIG. 4 shows an exploded view of the reactor 1 of the present embodiment. As shown in FIG. 4, in this embodiment, a fixing member 40 is used to fix the core 20 and the coils 31 and 32 to the case 10.

  As shown in FIGS. 1, 2, and 4, one fixing member 40 is provided on each side in the width direction of the reactor 1. As shown in FIG. 4, the fixing member 40 has through-holes 45 a to be described later. Bolts 61 are passed through the through-holes 45 a, and then the bolts 61 are placed on both ends of the case 10 in the width direction. Therefore, it is fixed to the case 10 by being screwed into a screw 11a (only the right side in the width direction is shown in FIG. 4). In this embodiment, the fixing member 40 is configured to press and hold the core 20 independently from the upper and lower sides in the vertical direction, and the pair of fixing members cooperate to core from the outer side in the width direction toward the inner side. 20 is pressed and held.

  The characteristics of the fixing member 40 will be described below. 2 is a front view of the right-side fixing member 40 projected in the depth direction, a side view of the case 10 projected in the width direction from the inside (ie, the left side in FIG. 2), and a width from the outside of the case 10 (ie, the right side in FIG. 2). 5 (a), (b), (c), (d) and (e) are a side view projected in the direction, a top view projected from the upper side in the vertical direction, and a bottom view projected from the lower side in the vertical direction. Each one is shown.

  As shown in FIG. 5A, the fixing member 40 is formed by bending a metal plate such as a stainless steel plate into an L shape at the first corner portion 43. Further, at the first corner portion 43, the fixing member 40 has a plate-like portion 42 on the side bent substantially vertically (a direction substantially parallel to the vertical direction) and the plate-like portion via the first corner portion 43. 42 is divided into upper tongue pieces located on the opposite side of 42. Further, the fixing member 40 is bent at the first corner portion 43 so that the tip portion 41a of the upper tongue piece portion 41 is directed obliquely to the lower left in FIG.

  Further, as shown in FIG. 5C, an upper tongue piece is formed from the plate-like portion 42 on the side bent substantially perpendicular to the first corner portion 43 (a direction substantially parallel to the vertical direction). An inverted U-shaped notch 44 is formed over the base end portion 41 b of the portion 41. In the plate-like portion 42 and the upper tongue piece portion 41, a portion inside the notch 44 is bent in an L shape outward in the width direction, and a fixing arm 45 is formed. A through hole 45a through which a bolt 61 (FIGS. 2 and 4) passes when the fixing member 40 is fixed to the case 10 is formed in the fixing arm 45 as shown in FIGS. 5 (d) and 5 (e). Has been.

  As shown in FIGS. 5B and 5C, the plate-like portion 42 is formed with two slits 46 extending from the middle of the plate-like portion 42 toward the lower side in the vertical direction. Among the plate-like portions 42 divided by the slits 46, those formed at both ends in the depth direction are bent in a U shape toward the inner side in the width direction as shown in FIG. 5A. A biasing arm 42a is formed.

  Further, a portion of the plate-like portion 42 sandwiched between the pair of slits 46 forms a lower tongue piece portion 47 bent in an L shape toward the inner side in the width direction. The lower tongue piece portion 47 is bent from the base end portion 47b to the tip end portion 47a toward the upper left side in FIG. 5A.

  As shown in FIG. 2, the upper tongue piece 41 extends in a direction along the upper surface 21 c of the U-shaped core 21 of the core 20. Similarly, the lower tongue piece portion 47 extends in a direction along the lower surface 21 d of the U-shaped core 21 of the core 20. For this reason, when the pair of fixing members 40 are attached to the core 20, the core 20 is sandwiched between the upper tongue piece portion 41 and the lower tongue piece portion 47 from both ends in the vertical direction.

  Moreover, a pair of fixing member is arrange | positioned so that the core 20 may be pinched | interposed from the width direction both ends. In this state, when each fixing member 40 is fixed to the case 10 with the bolt 61, the plate-like portion 42 of each fixing member 40 is sandwiched between the inner side surface 13 in the width direction of the case 10 and the core 20. It has become. That is, the distal end portion 42 c of the width direction urging arm 42 a comes into contact with the core 20. Further, since the base end portion 42 b of the width direction biasing arm 42 a extends in the direction along the inner side surface 13 of the case 10, the base end portion 42 b contacts the inner side surface 13 of the case 10. The width-direction biasing arm 42a is pressed in the width direction between the inner surface 13 of the case 10 and the core 20, and the repulsive force causes the tip end portion 42c of the width-direction biasing arm 42a to push the core 20 to the opposite side in the width direction. It urges | biases toward the fixing member 40 arrange | positioned. That is, the width direction urging arm 42a functions as a kind of leaf spring for urging the core 20 in the width direction. And the core 20 is hold | maintained by the width direction biasing arm 42a of a pair of fixing member 40 so that it may not move to the width direction.

  In the present embodiment, as described above, the fixing member 40 biases the core 20 in the width direction (that is, the normal direction of the bonding surfaces of the U-shaped core 21 and the I-shaped cores 22a and 22b). In addition, a load in the normal direction is applied to the adhesive surface. For this reason, even if shear stress in the surface direction of the bonding surface is applied to the core 20 due to thermal expansion of the core 20 or the like, the bonding is not easily peeled off.

  Further, as shown in FIG. 5D, the depth dimension of the upper tongue piece 41 of the fixing member 40 (the width of the upper tongue piece 41) is from the base end 41b toward the tip 41a. The tip 41a is narrowed so that the tip 41a is located at the approximate center in the depth direction. Since the upper tongue piece 41 has such a shape, the bending stress applied to the upper tongue piece 41 is dispersed, and stress concentration on a specific portion of the upper tongue piece 41 is prevented.

  Similarly, as shown in FIG. 5 (e), the depth direction dimension of the lower tongue piece portion 47 of the fixing member 40 (the width of the lower tongue piece portion 41) goes from the proximal end portion 47b toward the distal end portion 47a. The tip portion 47a is located at a substantially central portion in the depth direction. Since the lower tongue piece 41 has such a shape, the bending stress applied to the lower tongue piece 47 is dispersed, and stress concentration on a specific portion of the lower tongue piece 47 is prevented.

  As shown in FIG. 2, the distal end portion 42 c of the width direction urging arm 42 a of the fixing member 40 is folded outward in a dogleg shape at a contact portion 42 d that contacts the core 20. For this reason, the edge part 42e of the front-end | tip part 42c does not contact | abut to the core 20, and the core 20 is not damaged by the edge part 42e.

  As shown in FIG. 2, the upper tongue piece 41 of the fixing member 40 is located above the core 20, and the tip 41 a of the upper tongue piece 41 is the U-shaped core 21 of the core 20. It is in contact with the upper surface 21c. A tip 41 a of the upper tongue piece 41 of the fixing member 40 is folded upward in a U shape at a contact portion 41 c that contacts the core 20. For this reason, the edge part 41d of the front-end | tip part 41a does not contact | abut to the core 20, and the core 20 is not damaged by the edge part 41d.

  Similarly, the lower tongue piece portion 47 of the fixing member 40 is located below the core 20, and the tip portion 47 a of the lower tongue piece portion 47 is in contact with the lower surface 21 d of the U-shaped core 21 of the core 20. Yes. A distal end portion 47 a of the lower tongue piece portion 47 of the fixing member 40 is folded downward in a U shape at a contact portion 47 c that contacts the core 20. For this reason, the edge part 47d of the front-end | tip part 47a does not contact | abut to the core 20, and the core 20 is not damaged by the edge part 47d.

  When the core 20 is sandwiched between the upper tongue piece 41 and the lower tongue piece 47, the upper tongue piece 41 is deformed upward, and the lower tongue piece 47 is directed downward. Deform. Due to the repulsive force of the upper tongue piece 41 and the lower tongue piece 47 against the above deformation, the upper tongue piece 41 urges the core 20 downward, and the lower tongue piece 47 raises the core 20 upward. Energize towards. That is, the upper tongue piece 41 and the lower tongue piece 47 function as a kind of leaf spring that urges the core 20 downward and upward, respectively. In the present embodiment, the spring constants of the upper tongue piece 41 and the lower tongue piece 47 (that is, the spring constants of the upper tongue piece 41 and the lower tongue piece 47 (i.e. The load applied to the core 20 from the upper tongue portion 41 and the lower tongue portion 47) is adjusted to a desired size.

  As described above, the core 20 is lifted from the bottom surface 12 (FIG. 2) of the case 10 and does not move in the vertical direction by the two pairs of leaf springs composed of the upper tongue portion 41 and the lower tongue portion 47. Retained.

  As shown in FIGS. 2, 5 (a), 5 (d) and 5 (e), the contact portion 41 c of the upper tongue piece portion 41 is the contact portion 47 c of the lower tongue piece portion 47. It is arranged right above. For this reason, the stress due to the load applied to the core 20 from the upper tongue portion 41 and the lower tongue portion 47 is mainly compressive stress, and almost no moment that rotates the core 20 is applied to the core 20. It is like that.

  The core 20 and the windings 31 and 32 are accommodated in the case 10 by sandwiching the core 20 by the fixing members 40 from both sides in the width direction, and further accommodating the core 20, the windings 31 and 32, and the pair of fixing members 40 in the case 10. Then, the fixing member 40 is fixed to the case 10 with the bolt 61. In addition, after fixing the fixing member 40 to the case 10, a resin mold such as epoxy resin is injected into the case 10, and the core 20 and the windings 31 and 32 are more firmly held in the case 10.

  In the state where the core 20 and the windings 31 and 32 are held and accommodated in the case 10, as described above, the core 20 is sandwiched between the upper tongue portion 41 and the lower tongue portion 47, It is supposed to be retained. In this state, the core 20 is lifted from the bottom surface 12 of the case 10. As described above, in the reactor 1 of the present embodiment, the core 20 and the bottom surface of the case 10 are not in direct contact. Therefore, the vibration of the core 20 that may occur when the reactor 1 is used (when the coils 31 and 32 are energized). The transmission to the case 10 is greatly reduced, and the noise during use of the reactor 1 can be greatly reduced.

  In the embodiment of the present invention described above, two fixing members 40 are provided, one on each side in the width direction of the reactor 1, but the present invention is limited to the above configuration. Instead, only one fixing member 40 may be provided on one side in the width direction. In this case, the width direction biasing arm 42a of the fixing member biases the core 20 so as to press the core 20 against the inner peripheral side surface 13 of the case 10 opposite to the side where the fixing member 40 is provided. To do.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Case 12 Bottom surface 13 Inner side surface 20 Core 31, 32 Winding 40 Fixing member 41 Upper tongue piece part 42 Plate-like part 42a Width direction biasing arm 47 Lower tongue piece part

Claims (8)

A bowl-shaped case,
A core housed in the case;
A winding wound around a portion of the core;
A fixing member that is fixed to the case and holds the core so that the core does not contact the bottom surface of the case;
The fixing member is a first holding portion that is a leaf spring that abuts against the first surface of the core that is proximal to the opening of the case and biases the core toward the bottom surface of the case; A second holding portion that is a leaf spring that abuts against the second surface of the core that is proximal to the bottom surface of the case and biases the core toward the opening of the case; and abuts against the side surface of the core And a third holding portion that is a leaf spring that urges the core toward the inner side surface of the case.   2. The inductor according to claim 1, wherein a dimension in the width direction of the first holding portion is reduced from a proximal end portion to a distal end portion of the first holding portion.   3. The inductor according to claim 1, wherein a dimension in the width direction of the second holding portion is reduced from a proximal end portion to a distal end portion of the second holding portion.   The contact portion that contacts the core in the first holding portion and the contact portion that contacts the core in the second holding portion are arranged side by side in a direction from the opening of the case toward the bottom surface. The inductor according to any one of claims 1 to 3, wherein the inductor is provided.   The third holding portion is disposed between the side surface of the core and the inner side surface of the case and has a plate-like base end portion extending in a direction along the inner side surface of the case, and the base end portion. The inductor according to any one of claims 1 to 4, further comprising a tip portion bent in a U-shape from one end on the bottom surface side of the case and abutting against a side surface of the core.   The first holding portion has a distal end portion that is bent in a substantially L shape from a plate-like portion including a base end portion of the third holding portion and extends in a direction toward the first surface of the core, 6. The inductor according to claim 1, wherein a part of the tip portion abuts on a first surface of the core and biases the core. The plate-like part including the base end part of the third holding part is divided into three parts by two slits extending from the opening of the case toward the bottom surface,
Of the three parts of the divided plate-like part, the third holding part is formed in two parts at both ends,
The second holding portion is bent in a substantially L shape from a portion sandwiched between the third holding portions among the three portions of the divided plate-like portion, and is formed on the second surface of the core. 7. The device according to claim 1, further comprising a tip portion that extends in a direction in which the core portion urges the core by abutting a part of the tip portion against the second surface of the core. The inductor described in 1. The inductor according to claim 1, comprising a plurality of sets of the fixing members.

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