JP2011135091A - Magnetic core, and coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil component that is improved in industrial availability and economical efficiency by enhancing size reduction, resource saving, and energy saving with constitution with greatly improved DC superposition characteristics, and also easily automating winding. <P>SOLUTION: A magnetic core 10 has a magnetic gap 6 formed of: a bent core end 3 of a rod-like core, made of a soft magnetic body having a pair of core ends 3 and 4; and a core side face 5 adjoining the other core end 4 by bending the one end and putting it closer. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a coil component used in electronic devices such as a power supply circuit and an inverter, and more particularly to a technology for constructing a small and high-performance coil component.

  Conventionally, in coil components wound around a magnetic core of a closed magnetic path, an appropriate gap (gap) is provided on the magnetic path of the magnetic core as a measure to prevent a decrease in the inductance value of the coil when DC is superimposed. Methods have been taken to reduce this.

  FIG. 10 is a front view showing an example of a conventional coil component. Referring to FIG. 10, the coil component 50 includes a winding 42 wound around a toroidal core 41 having a gap 46. FIG. 11 is an enlarged view of a gap portion of the toroidal core of the coil component 50 of FIG. The toroidal core 41 has a shape having a pair of end faces 43 and 44 facing each other with the magnetic gap 46 interposed therebetween, and the core end faces face each other. In this case, the winding 42 (see FIG. 10) is in a situation where it must be relied mainly on manual winding.

  In particular, in the case of a magnetic body having a relative permeability μ of about 100, such as a metal-based dust core, in the conventional type core shown in FIGS. 10 and 11, when the magnetic gap is widened, there is a change such as a decrease in the inductance value of the coil. It has a significant disadvantage.

  12 (a) and 12 (b) are diagrams showing the assembly of another example of a coil component according to the prior art. As shown in FIG. 12, the coil component is configured by mounting a coil 62 wound through a magnetic gap. In addition, some coil components that can be retrofitted with an air-core coil as shown in FIG. 12 have been put into practical use as a conventional product, but the tip 64 of the core, which is the entrance of the wound coil, has an acute angle. Therefore, there is a problem in strength because the tip portion is easily chipped, such as in the case of a core manufactured by press molding of a compact such as dust, and its application has been limited to some materials such as metal-based laminated steel sheets.

  On the other hand, a semi-closed magnetic circuit inductor shown in FIGS. 13 and 14 has been proposed as an example in which FIG. 10 is further improved (see Patent Document 1). FIG. 13 is a front view showing the semi-closed magnetic circuit inductor 100, and FIGS. 14A and 14B are front views showing a core of the inductor of FIG. As shown in FIGS. 13 and 14, the rectangular cylindrical coil space formed by winding the copper wire 102 in advance by separating the cut surface of the magnetic core from which the part 103 of the annular closed magnetic path magnetic core 101 is cut. After being inserted into the core, the cut surface 104 is joined to form an annular semi-closed magnetic path magnetic core, thereby completing the semi-closed magnetic circuit inductor 100.

  Further, as an example similar to FIGS. 12A and 12B, a choke coil device as shown in FIGS. 15 and 16 is disclosed (see Japanese Patent Laid-Open No. 2000-277337). FIG. 15 is a front view showing a core of a conventional choke coil device, and FIGS. 16A to 16A are front views for explaining the assembly of the choke coil device using the core of FIG. As shown in FIG. 15, the choke coil device 110 creates a core 114 having a magnetic gap 41a, and creates an air-core coil 115 shown in FIG. The air-core coil 115 is attached to the periphery of the core 114 by inserting a part of the air-core coil 115 into the central hole of the core 114 from the gap 113 of the core 114. As shown in FIG. 16B, the air-core coil 115 is elastically deformed along the arc shape of the core 114, and the entire length is mounted around the core 114. Thereafter, a non-magnetic material or a non-conductive spacer 116 made of a magnetic material is attached to the gap 113 of the core 114 and fixed. As shown in FIG. 16C, the choke coil device is completed by adjusting the winding pitch of the air-core coil 50 and further forming lead portions.

JP 2001-85233 A

  However, in the method according to the prior art described above, as a result of providing the air gap on the magnetic path, the effective μ is lowered, and it is necessary to wind up the coil in order to obtain a necessary inductance value. As a result, the DC resistance of the wound coil is reduced. In addition, the copper loss has been worsened and the outer shape of the coil has increased, resulting in serious drawbacks in that it is difficult to realize a small component, low loss, and resource saving.

  In addition, when winding on a magnetic core of a closed magnetic circuit, winding is difficult and the specifications for mechanical winding are limited, which hinders automation and is industrially inappropriate.

  On the other hand, as shown in FIGS. 12, 15, and 16 described above, in the magnetic core of the closed magnetic circuit with the gap, the mechanical winding is performed by inserting the air core coil pre-wound from the gap into a coil. Although some methods have been put to practical use, it is not suitable for a device that requires a high inductance value because it requires a gap enough to accommodate a wound coil. In addition, since the tip of the core that contains the wound coil has an acute angle, there is a problem in strength that the tip flaws are easily chipped, such as in the case of a core manufactured by press molding of dust compacts. The application has been limited to some materials such as metal-based laminated steel sheets.

  Therefore, the present invention solves such problems of the prior art, and has a structure in which direct current superimposition characteristics are greatly improved to improve downsizing, resource saving and energy saving, and to easily automate windings. It is a technical problem to provide coil parts that have been realized and have improved industrial efficiency and economic efficiency.

  In order to solve the above-described problems, according to the present invention, both ends of a rod-shaped core made of a soft magnetic material having a pair of end surfaces are folded back to each other so that the core side surface adjacent to the folded end surface is adjacent to the other core end surface. A magnetic core having a gap portion formed between the core side surface and having a gap width equal to or greater than the thickness of the air-core coil attached to the magnetic core is obtained.

  Further, according to the present invention, there is obtained a magnetic core characterized in that in the magnetic core, the rod-shaped core is folded at both ends so as to have an arc of ¼ arc or less and ½ or more. .

  According to the present invention, it is possible to obtain a magnetic core characterized in that at least one protrusion is provided on the side surface of the core in the magnetic core.

  According to the present invention, in any one of the magnetic cores, the gap portion has a structure backfilled with a filler containing at least a magnetic body or a non-magnetic body. Is obtained.

  Further, according to the present invention, there is provided a coil component including any one of the magnetic cores and a winding provided on the magnetic core, wherein the air core coil is inserted from one end face of the core. A coil component characterized by being a wound coil is obtained.

  When the coil component according to the present invention is used, the direct current superimposition characteristics can be greatly improved. Therefore, in obtaining the inductance for the desired current rating, the miniaturization, resource saving, and energy saving which are the mission of the electronic equipment are improved, and the winding It is possible to provide a coil component that can be easily automated, and it can be said that it is extremely large in terms of industrial gain.

It is a figure which shows the coil components by the 1st Embodiment of this invention. It is a figure where it uses for description of the assembly of the coil components of FIG. It is a figure used for description of an effect | action of the coil components of FIG. 1, and is the elements on larger scale which show a gap part. FIG. 4 is a view showing a coil component according to the second embodiment of the present invention. It is a figure with which it uses for description of an effect | action of the coil components of FIG. 4, and is the elements on larger scale which show a gap part. It is a figure which shows the coil components by the 3rd Embodiment of this invention. It is a figure with which it uses for description of an effect | action of the coil components of FIG. 6, and is the elements on larger scale which show a gap part. It is a front view which shows the coil components by the 4th Embodiment of this invention. It is a front view which shows the coil components by the 5th Embodiment of this invention. It is a front view which shows an example of the coil components by a prior art. It is the figure which expanded the gap part of the core of FIG. (A) And (b) is a figure which shows the assembly of another example of the coil components by a prior art. It is a figure which shows the semi-closed magnetic circuit inductor by a prior art. It is a figure which shows the core of the semi-closed magnetic circuit inductor of FIG. 13, (a) is a front view, (b) is a side view. It is a front view which shows the core of the choke coil apparatus by a prior art. It is a figure which shows the assembly of the choke coil apparatus using the core of FIG.

  Next, embodiments according to the present invention will be described in detail with reference to the drawings.

  In the embodiment of the present invention, an example in which a magnetic material of a metal dust core (about μ = 100) is used as a core core of a soft magnetic material will be described.

  FIG. 1 is a front view showing a coil component according to a first embodiment of the present invention. 2 is a diagram for explaining the assembly of the coil component of FIG. 1, and FIG. 3 is a partially enlarged front view for explaining the operation of the coil component of FIG. 1 and FIG.

  Referring to FIG. 1, a magnetic core (core) 1 is substantially circular with a straight portion, folded back on one core end surface 3 side of a rod-shaped core having a pair of end surfaces (hereinafter referred to as core end surfaces) 3 and 4 A winding is applied to the magnetic core 1 having a magnetic gap 6 formed between the core end surface 3 and the core side surface 5 so as to approach one core end surface 4 side. Here, in the case of the coil component wound on the conventional gap-shaped toroidal core shown in FIG. 10 described above, the windings were mainly dependent on manual winding.

  On the other hand, in the coil component according to the first embodiment of the present invention, the core end surface 3 and the core side surface 5 face each other to form the magnetic gap 6 as shown in FIG. If there is a gap width that allows the coil 2 to pass through, it is easy to insert the air-core coil 2 as shown in FIG. 2, and the winding can be automated.

  Further, since the magnetic gap 6 is such that the core end face 3 and the core side face 5 face each other, particularly in the case of a magnetic body having a relative permeability μ of about 100, such as a metal dust core, the magnetic flux is formed on the core side face 15 as shown in FIG. As compared with the conventional core shown in FIG. 10, even if the magnetic gap is widened, the decrease in the inductance value of the coil is relatively small, and it is possible to automate the winding by inserting the air-core coil. Correspondence becomes easy.

  FIG. 4 is a front view showing a coil component according to the second embodiment of the present invention. FIG. 5 is a diagram for explaining the operation of the coil component of FIG. Referring to FIG. 4, the coil component 20 folds one core end surface 13 side of a rod-shaped core having a pair of end surfaces (core end surfaces) 13, 14, approaches the other core end surface 14 side, An air core coil 12 is mounted on a magnetic core 11 having a magnetic gap 16 formed between the core side surface 15 and a winding is applied. Furthermore, it has the protrusion part 18 of the shape which made the core cross-sectional area S2 orthogonal to a magnetic path in the vicinity of the end surface including the turned end surface 13 larger than the core average cross-sectional area S1 of a magnetic path.

  In the case of the second embodiment, as shown in FIG. 5, the core end face 13 is also widened, so that the width W3 of the magnetic gap is further widened and it is easy to cope with automation.

  In the case of the second embodiment, as another effect, the tip of the air-core coil 12 hits the protrusion 18 and serves to prevent the coil from coming off.

  FIG. 6 is a front view showing a coil component according to the third embodiment of the present invention. FIG. 7 is a partially enlarged view for explaining the operation of the coil component of FIG. Referring to FIG. 6, the coil component 30 has a pair of end faces (hereinafter referred to as “core end faces”) 23, 24 which are folded back so that both ends of the rod-shaped core are close to each other. Winding is performed by attaching an air core coil 22 to a magnetic core 21 having a magnetic gap 26 formed between a core side face 25 adjacent to one core end face 24.

  In FIG. 6, the side surfaces 25 and 27 of the core face each other to form a magnetic gap 26. This also has the effect of widening the gap as shown in FIG. Automation can be realized easily.

  FIG. 8 is a front view showing a coil component according to the fourth embodiment of the present invention. Referring to FIG. 8, the coil component 40 has a pair of end faces (hereinafter referred to as “core end faces”) 33 and 34, folded back at one end 33 side of the rod-shaped core, and brought close to the other end 34 side. An air core coil 39 is attached to a magnetic core 31 having a magnetic gap 36 formed between the core side surface 35 and a winding is applied. Furthermore, a protrusion 39 is provided on a part of the side surface of the core inner periphery of the magnetic core 31. The air-core coil 32 is inserted through the core end surface 34 as in the previous example.

  FIG. 9 is a front view showing a coil component according to the fifth embodiment of the present invention. As shown in FIG. 9, in the fifth embodiment, a spacer 9 made of a magnetic material having a width slightly narrower than the gap width is embedded in the gap portion 6 of the first embodiment.

  In all the cores of FIGS. 1, 4 and 6 described above, the positioning of the tip of the air core coil by post-insertion is performed as shown in the embodiment of FIG. 8 regardless of the winding width of the air core coil. It can be easily realized by the method according to the present invention.

  Further, in all the coil components of the first to fourth embodiments, the purpose of increasing the inductance value, suppressing the leakage magnetic flux generated from the gap, or suppressing the vibration of the core due to magnetostriction is shown in FIG. As shown in the fifth embodiment, by filling back the gap material 9 made of magnetism or non-magnetism in the gap portion 6, it is easy to cope with them, and an optimum design is possible by combination.

  In addition, as described above with reference to FIG. 12, some coil components that can be retrofitted with an air-core coil have been put to practical use. Therefore, there is a problem in strength that the tip part is easily chipped, such as in the case of cores manufactured by press molding of compacts such as dust, and its application is limited to some materials such as metal laminated steel sheets. It was. On the other hand, since the core tip portion according to the present invention does not need to have an acute angle, it can be applied to dust-type press molding such as a dust compact system, and its application field is very wide.

  As described above, the application of the present invention is not limited to the embodiment of the present invention, but can be applied to all coil parts using other cores with gaps (magnetic cores), and its application fields are very wide.

  In addition, as the material of the magnetic core according to the present invention, any soft magnetic material such as dust, laminated steel, or ferrite can be used.

  As is apparent from the above description, the coil component according to the present invention is applied to a circuit element of a miniaturized electronic device.

DESCRIPTION OF SYMBOLS 1 Magnetic core 2 Air core coil 3, 4 End surface 5 Core side surface 6 Magnetic gap 9 Spacer 11 Magnetic core 12 Air core coil 13, 14 End surface 15 Core side surface 16 Magnetic gap 18 Protrusion part 20 Coil parts 23, 24 Core end surface 21 Magnetic core 27 Core side surface 25 Core side surface 26 Magnetic gap 22 Air core coil 30 Coil component 31 Magnetic core 32 Air core coil 33, 34 End surface 35 Core side surface 36 Magnetic gap 39 Protrusion part 40 Coil component 41 Toroidal core 41a Magnetic gap 42 Winding 43, 44 End face 46 Gap 50 Coil parts 62 Coil 64 Tip part 114 Core 115 Air core coil 113 Gap 116 Spacer

Claims (5)

  Formed between the core side surface adjacent to the folded end surface and the core side surface adjacent to the other core end surface by attaching both ends of the rod-shaped core made of a soft magnetic material having a pair of end surfaces to each other, and attached to the magnetic core A magnetic core having a gap portion having a gap width equal to or greater than a thickness of an air core coil to be manufactured.   2. The magnetic core according to claim 1, wherein both ends of the rod-shaped core are folded back so as to have an arc of ¼ arc or less and ½ or more.   3. The magnetic core according to claim 1, wherein at least one protrusion is provided on a side surface of the core. 4.   The magnetic core according to any one of claims 1 to 3, wherein the gap portion has a structure backfilled with a filler containing at least a magnetic body or a non-magnetic body. Magnetic core.   It is a coil component provided with the magnetic core as described in any one of Claims 1-4, and the coil | winding provided in the said magnetic core, Comprising: The said air core coil is inserted from one said core end surface Coil parts characterized in that they are wound coils.

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