JP2011222590A - Coil component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil component which works quietly even when used within the human audible frequency range.SOLUTION: A coil component comprises a triple layered compound magnetic core laminating closed magnetic circuit cores 4 at each of upper and lower layers of a C-shaped core 5 in the thickness direction. A magnetic gap of the C-shaped core 5 is firmly fixed by being confined with the upper and lower layers of the closed magnetic circuit cores 4, thus a vibration yielded by a magnetic attraction force between magnetic substances facing the magnetic gap part is suppressed.

Description

  The present invention relates to a wire ring component equipped in a rectifier circuit, a noise prevention circuit, a resonance circuit, and the like in various AC devices, and a component configuration thereof.

  In the prior art described in Patent Document 1, a C-shaped core having a magnetic gap portion is created, and a resin is used as a material so as to fill the magnetic gap portion and simultaneously cover the C-shaped core surface. There has been disclosed a toroidal coil that can be automated by molding, can be automated, and has no risk of damage even if an exciting force is applied to the core by energizing the coil.

JP 2002-93627 A

  Even with the prior art described in Patent Document 1, a core excitation force is generated by energization. In particular, when the frequency of the energizing current is 20 kHz or less, it is applied to the audible region, so the problem of noise caused by the core excitation force still remains.

  The present invention includes a C-shaped core having a magnetic gap, and at least one closed magnetic path core laminated adjacent to the C-shaped core, wherein the C-shaped core and the closed magnetic path core each have an inner circumferential surface. An outer peripheral surface, and a spacer made of an insulating material is arranged in the magnetic gap in the C-shaped core and the joint portion of the C-shaped core and the closed magnetic path core, and the C-shaped core The magnetic gap solves the above problem by a wire ring component adjacent to the magnetic body portion of the closed magnetic path core via the joint portion.

  In the prior art described in Patent Document 1, a core exciting force is generated by applying a magnetic attraction to the magnetic bodies facing the magnetic gap portion by energizing the coil. Therefore, in the present invention, a magnetic attractive force due to energization is generated between the C-shaped core and the closed magnet by configuring the magnetic body of the closed magnetic path core adjacent to the magnetic gap of the C-shaped core corresponding to the configuration described in Patent Document 1. Since the magnetic attraction force is also distributed between the road cores, the core excitation force is also distributed and reduced. Moreover, since the magnetic body adjacent to the magnetic gap is higher in rigidity than the insulating material, the magnetic gap can be firmly fixed, and vibration caused by the core excitation force can be suppressed. Further, a magnetic material such as MnZn ferrite having a different material from that of the C-shaped core may be inserted into the magnetic gap of the C-shaped core. The term closed magnetic path core is used to include a magnetic core without a magnetic gap whose magnetic path is limited to a magnetic body only. It is used to include a limited magnetic core. Therefore, for example, a closed magnetic circuit core includes a magnetic core such as a C-shape. Further, it is desirable that the inner peripheral surface and the outer peripheral surface of the C-shaped core and the closed magnetic circuit core are continuous through the joint portion in order to improve the workability of the winding.

  Insulating materials include curable acrylic resins, thermosetting polyethylene resins, curable epoxy resins, curable silicone resins, thermoplastic PBT resins, thermoplastic phenol resins, thermoplastic PBT, thermoplastic PC resins, etc. Alumina, glass, cement, and the like are available, but those having as high rigidity as possible, that is, Young's modulus, are desirable as long as core cracks do not occur so that the vibration of the core can be suppressed. In the case of a wire ring component having high inductance, magnetic material powder such as MnZn ferrite powder or FeSiAl soft magnetic metal powder may be blended in the insulating material. In addition, if the R (curvature radius) of the edge of the insulating material located on the outer side of the core is 10 times or more the thickness of the clothing layer of the clothing conductor, sufficient insulation is ensured to prevent rare shorts between the conductors. it can.

  Further, in the present invention, the above-mentioned problem is achieved by further providing a wire ring component in which all of the inner peripheral surface and the outer peripheral surface of the C-shaped core and the closed magnetic path core are covered with a coating layer of the insulating material. Contribute to the solution.

  Since many closed magnetic circuit cores are not sufficiently insulating, it is necessary to devise measures to ensure insulation by covering the core surface with an insulating material, but when the closed magnetic circuit core material is easily cracked, etc. Rather than completely covering the surface, exposing a part of the surface can prevent core cracking due to stress concentration of the coated insulating material. The exposed surface of the closed magnetic path core can be reliably provided with an insulating property by adhering or sticking a separately made lid made of an insulating material.

  Further, in the present invention, the closed magnetic path core is composed of a plurality of magnetic body pieces, and a wire ring component in which the spacer is arranged in a gap between the adjacent magnetic body pieces contributes to the solution of the above problem. .

  When a magnetic material having a high magnetic permeability is used as the closed magnetic path core material, magnetic saturation is likely to occur, so a magnetic gap needs to be provided. In addition, when the closed magnetic circuit core breaks due to the stress when molding the insulating material, the closed magnetic circuit core is divided into a plurality of magnetic body pieces, and the magnetic gap between the magnetic body pieces is filled with the insulating material for insulation. Stress due to the material is further dispersed, and core cracks can be prevented more reliably.

  Furthermore, the present invention further contributes to the solution of the above problems by using a wire ring part in which the insulating material is formed by molding.

  For surface coating and gap filling in the present invention, a C-shaped core and a closed magnetic path core are fixed in a mold using an insulating spacer, and a thermosetting resin or a thermoplastic resin is added to the insulating spacer together with the insulating spacer. It is preferred to inject and cure.

  Further, in the present invention, the insulating material filling the magnetic gap and all the C-shaped core surfaces are formed by molding, and at the same time, the insulating portions at locations corresponding to the inner peripheral surface and the outer peripheral surface of the closed magnetic path core. After forming a material as a core case in advance, the closed magnetic path core is used as a wire ring component mounted on the core case, thereby contributing to the solution of the above-described problem.

  Further, in the present invention, all of the C-shaped core surface and the insulating material filling the magnetic gap are formed by molding, and at the same time, all of the inner peripheral surface and the outer peripheral surface of the closed magnetic path core, and the magnetic body The insulating material is previously formed as a magnetic piece case in the gap between the pieces, and then the magnetic piece is used as a wire ring part mounted on the magnetic piece case, thereby contributing to the solution of the above-mentioned problem.

  Even if the closed magnetic circuit core is divided into a plurality of magnetic pieces, the core may be cracked by molding the insulating material. In this case, the insulating material is formed in advance as a case molded with the C-shaped core, and a closed magnetic path core or a magnetic piece is put into the case and bonded. If sufficient rigidity can be secured in the case, it is desirable to use an epoxy resin, a silicone resin, or a pressure-sensitive adhesive having a low Young's modulus as an adhesive because the core can be surely prevented. In addition, it is desirable to provide a small concavo-convex corresponding to the case and the core, and to have a snap-fit structure that can be fixed simply by fitting the core into the case, because it can be fixed without using an adhesive or an adhesive.

  In the present invention, the C-shaped core material further contributes to the solution of the above-described problems by making the ring-shaped ring part has a saturation magnetization larger than that of the closed magnetic path core material and a smaller magnetic permeability.

  By configuring the C-shaped core and the closed magnetic circuit core with different magnetic materials, it is possible to make use of the side surfaces excellent in mutual magnetic characteristics and suppress the disadvantageous side surfaces. For example, when the C-shaped core material is a laminated silicon steel plate and the closed magnetic path core material is MnZn ferrite, the laminated silicon steel plate has both the high saturation magnetization, the low core loss of the MnZn ferrite, and the high magnetic permeability. It can be a wire ring part. That is, the low magnetic permeability and high core loss of the laminated silicon steel sheet can be supplemented by the magnetic properties of MnZn ferrite. The C-shaped core material is preferably an iron core with high saturation magnetization, a silicon steel plate, an amorphous laminated magnetic core, or the like, and the closed magnetic path core material is preferably MnZn ferrite or the like that is superior in permeability and core loss.

  According to the present invention, the vibration of the core is suppressed, and a silent ring component can be provided even when used at a frequency in the human audible range (applying current with an AC signal of 25 kHz or less).

  The wire ring component of the present invention preferably has saturation magnetization, that is, a DC superposition characteristic that maintains the inductance even when a DC current is applied, and has high power conversion efficiency due to high inductance and low core loss.

  Furthermore, the wire ring component of the present invention does not generate core cracks, and since there is no characteristic variation due to core cracks and no noise generation from the core cracked part, the reliability in terms of characteristics and quietness can be further improved. .

It is a perspective view of the magnetic core in the embodiment of the present invention. It is sectional drawing of the magnetic core in embodiment of this invention. FIG. 2A, FIG. 2B, FIG. 2C, and FIG. 2D are examples of magnetic core cross-sectional views in the embodiment of the present invention. It is a figure which shows the closed magnetic circuit core in embodiment of this invention. FIG. 3A and FIG. 3B are perspective views of the closed magnetic path core in the embodiment of the present invention. FIG. 3C is an exploded view of the closed magnetic circuit core in the embodiment of the present invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  An example of the wire ring component in the present invention is shown in FIGS. FIG. 1 is a perspective view of a composite magnetic core 1 of a wire ring component according to the present invention. The composite magnetic core 1 has an annular shape, that is, a toroidal shape as shown in FIG. 1, which is suitable for good workability of the coil winding and versatility, but may be a quadrangular annular shape or an elliptical annular shape.

  A composite magnetic core 1 in FIG. 1 includes a covering insulating material 2 and a plurality of magnetic cores.

  FIG. 2A shows an example of the a-plane which is a cross section of the composite magnetic core in FIG. FIG. 2 (a) is a stack of a closed magnetic circuit core 4 and a C-shaped core 5 having a magnetic gap in FIG. 1, and an insulating material 3 is filled between the closed magnetic circuit core 4 and the C-shaped core 5, and the closed magnetic circuit is closed. It shows that the inner and outer peripheral surfaces of the core 4 and the C-shaped core 5 are all covered with the insulating material 3. By being covered with the insulating material 3, insulation between a coil (not shown) and the composite magnetic core is ensured. Further, in order to prevent stress concentration due to the insulating material mold in the closed magnetic path core 4 and the C-shaped core 5, there is an exposed portion that is not covered with the insulating material 3 on the end surface in the thickness direction of the composite magnetic body core 1. Since the insulating material 3 protrudes from the portion, the coil, the closed magnetic path core 4 and the C-shaped core 5 do not come into contact with each other, so that insulation is ensured. In order to make the insulation between the coil and the composite magnetic core more reliable, the insulating material cap 7 is bonded to the exposed portion of the closed magnetic circuit core 4 or the C-shaped core 5 with a silicone resin having a low Young's modulus or the like. You may adhere with a tape.

  The closed magnetic path core 4 may be provided with a plurality of magnetic gaps. Although not shown, the C-shaped core 5 is provided with a magnetic gap in at least one place on the core circumference.

  FIG. 2B is a diagram showing a cross section perpendicular to the magnetic path in the composite magnetic core 1 having a three-layer structure in which the closed magnetic path cores 4 are stacked on the upper and lower layers in the thickness direction of the C-shaped core 5. Since the magnetic gap of the C-shaped core 5 is confined by the upper and lower closed magnetic circuit cores 4, the effect of suppressing the vibration and noise of the core is higher than the configuration of FIG.

  FIG. 2C shows another example of the a-plane which is a cross section of the composite magnetic core in FIG. FIG. 2C is different from FIG. 2A in that the surface of only the C-shaped core 5 is covered with an insulating material. Since the C-shaped core 5 is a good conductor such as a silicon steel plate and a strong material is preferably used, the entire surface may be covered with an insulating material.

  FIG. 2D shows another example of the a-plane that is a cross section of the composite magnetic core in FIG. FIG. 2D shows a configuration in which a portion excluding the central portion of the exposed portion of the end surface in the thickness direction in FIG. Since the closed magnetic circuit core 4 is preferably made of a ferrite material having an electrical resistivity higher than that of the C-shaped core 5 and needs to prevent stress concentration of the insulating material 3, the exposed portion is more than the C-shaped core 5. Is spreading.

  In order to prevent the core breakage of the closed magnetic path core 4, it may be composed of a plurality of magnetic pieces as shown in FIG. 3. By dividing the closed magnetic path core into a plurality of magnetic body pieces in advance, the stress of the insulating material 3 can be dispersed and reduced.

  FIG. 3A shows a closed magnetic path core 4 composed of a plurality of magnetic body pieces 41. A magnetic gap between adjacent magnetic pieces is filled with an insulating material 31. The magnetic piece 41 may divide the closed magnetic path core 4 evenly along the radial line. However, by dividing the magnetic piece 41 along a straight line not along the radial line as shown in FIG. Since the magnetic saturation of the piece 41 occurs non-uniformly, it is desirable because the direct current superposition characteristics can be improved.

  FIG. 3B shows a closed magnetic path core 4 made of magnetic pieces 41 and 42 having different magnetic characteristics. In adjusting the required magnetic characteristics, all the magnetic pieces need not have the same magnetic characteristics or the same shape. Further, the magnetic gap between the magnetic pieces adjacent to each other need not be uniform, and a wide magnetic gap may be taken at a specific location like the insulating material filling portion 32 into the magnetic gap.

  FIG. 3C shows a configuration in which the insulating material 3 is formed in advance as a case of the magnetic piece 41 and the magnetic piece 41 is mounted on the case of the insulating material 3.

  An example of carrying out the present invention will be shown below. The ferrite material described below is MnZn ferrite having a magnetic permeability of about 2100, and the laminated silicon steel plate is a laminated silicon steel plate having a magnetic permeability of about 15000 and a thickness of 0.23 mm per sheet. In any case, the number of windings is 12 turns, the inner diameter of the magnetic core is 19 mm, the outer diameter is 38 mm, and the magnetic gap is 4 mm. The frequency of the energization current to the coil was 10 to 20 kHz, and the DC superimposed current that is the time average value of the energization current was 12A. Further, when the composite magnetic core 1 is formed by the closed magnetic path core 4 and the C-shaped core 5, the magnetic gaps are shifted from each other by 4 mm in the circumferential direction.

(Example 1)
A composite magnetic body core 1 using a thermosetting epoxy resin insulating material in the configuration of FIG. 2A and a closed magnetic circuit core 4 having a height of 7 mm made of a ferrite material and a C-shaped core 5 having a height of 7 mm made of a laminated silicon steel plate. Then, a coil was wound and a wire ring part was created (inductance was 600 microH). Next, the coil was swept from the low frequency to the high frequency at a frequency of 10 kHz / minute at a frequency in the human audible range (applying an AC signal of 25 kHz or less), and a questionnaire was given to 10 subjects about the noise of the ring components. As a result, three of them answered that they could hear noise from the wheel parts.

(Example 2)
A composite magnetic body core 1 using a thermosetting epoxy resin insulating material in the configuration of FIG. 2A and a closed magnetic circuit core 4 having a height of 7 mm made of a ferrite material and a C-shaped core 5 having a height of 7 mm made of a laminated silicon steel plate. Formed and wound a coil to create a wire ring part. Next, when the coil was energized in the same manner as in Example 1, the inductance was 600 μH. A questionnaire was conducted with 10 subjects about the noise of the wire ring parts in the energized state, and 3 of them answered that noise could be heard from the wire ring parts.

(Example 3)
Two magnetic closed cores 4 with a height of 3.5 mm made of ferrite material, and a C-shaped core 5 with a height of 7 mm made of laminated silicon steel plate and a composite magnetism using a thermosetting epoxy resin insulating material in the configuration of FIG. A body core 1 was formed, and a coil was wound to create a wire ring part. Next, when the coil was energized in the same manner as in Example 1, the inductance was 600 μH. When 10 subjects were asked about the noise of the wire ring parts in the energized state, all of them answered that no sound could be heard from the wire ring parts.

(Comparative example)
Only a C-shaped core 5 having a height of 14 mm made of a ferrite material was used, and a magnetic gap was filled and the core surface was covered with a thermosetting epoxy resin insulating material. Next, when the coil was energized in the same manner as in Example 1, the inductance was 600 μH. A questionnaire was conducted with 10 subjects about the noise of the wire ring parts in the energized state, and all responded that noise could be heard from the wire ring parts.

DESCRIPTION OF SYMBOLS 1 Composite magnetic body core 2 Insulating material coating | coated part 3 Insulating material 31 Insulating material filling part 32 Insulating material filling part 4 Closed magnetic path core 41 Magnetic body piece 42 Magnetic body piece 5 C-shaped core 61 Magnetic gap 62 Magnetic gap

Claims (8)

  A C-shaped core having a magnetic gap; and at least one closed magnetic circuit core laminated adjacent to the C-shaped core, wherein the C-shaped core and the closed magnetic circuit core each have an inner peripheral surface and an outer peripheral surface. And a spacer made of an insulating material is arranged in the magnetic gap in the C-shaped core and the joint portion of the C-shaped core and the closed magnetic path core, and the magnetic gap in the C-shaped core is A wire ring component characterized by being adjacent to a magnetic body portion in the closed magnetic path core via the joint portion.   The wire ring component according to claim 1, wherein all of the inner peripheral surface and the outer peripheral surface of the C-shaped core and the closed magnetic path core are covered with a coating layer made of the insulating material.   3. The wire ring component according to claim 1, wherein the closed magnetic path core is composed of a plurality of magnetic body pieces, and the spacer is arranged in a gap between the adjacent magnetic body pieces.   The wire ring component according to any one of claims 1 to 3, wherein the insulating material is formed by molding.   The insulating material that fills the entire C-shaped core surface and the magnetic gap is formed by molding, and at the same time, the insulating material at a location corresponding to all of the inner peripheral surface and the outer peripheral surface of the closed magnetic path core is used as a core case in advance. The wire ring component according to claim 2, wherein the closed magnetic circuit core is attached to the core case after being formed.   The insulating material that fills all the C-shaped core surface and the magnetic gap is formed by molding, and at the same time, a portion that hits the gap between the inner and outer peripheral surfaces of the closed magnetic path core and the magnetic piece. The wire ring component according to claim 3, wherein the insulating material is previously formed as a magnetic piece case and the magnetic piece is attached to the magnetic piece case.   The wire ring component according to any one of claims 1 to 6, wherein the C-shaped core material has a larger saturation magnetization and a lower magnetic permeability than the closed magnetic path core material.   The wire ring component according to any one of claims 1 to 7, wherein a magnetic body made of a material different from that of the C-shaped core is inserted into the magnetic gap of the C-shaped core.

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