JP2012028572A - Induction device - Google Patents

Induction device Download PDF

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JP2012028572A
JP2012028572A JP2010166088A JP2010166088A JP2012028572A JP 2012028572 A JP2012028572 A JP 2012028572A JP 2010166088 A JP2010166088 A JP 2010166088A JP 2010166088 A JP2010166088 A JP 2010166088A JP 2012028572 A JP2012028572 A JP 2012028572A
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core
resin material
shaped
mold resin
shaped core
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Hiroshi Ono
博史 大野
Shuji Yokota
修司 横田
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Toyota Industries Corp
Toyota Motor Corp
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Toyota Industries Corp
Toyota Motor Corp
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Abstract

PROBLEM TO BE SOLVED: To provide an induction device which can be manufactured easily, and which allows easy positioning of a core.SOLUTION: A U-type core 21 has ends 21a and 21b. A mold resin member 40 is molded so as to cover at least the ends 21a and 21b of the U-type core 21, and has cylindrical portions 46 and 47. A U-type core 22 has ends 22a and 22b. The ends 22a and 22b are press-fitted into the respective cylindrical portions 46 and 47 of the mold resin member 40 to thereby form a closed magnetic circuit together with the U-type core 21. Coils 30 and 31 are wound around the mold resin member 40.

Description

本発明は、誘導機器に関するものである。   The present invention relates to an induction device.

特許文献1においてリアクトルの構造が開示されている。詳しくは、中空筒状のボビンの外周部には螺旋状の溝が設けられ、この溝に沿って平角状の裸導体が巻回されている。また、細長いドーナッツ形状のコア部分を構成すべく、ボビンの中空部に、I型コア、U型コア、ギャップ材を順に圧入して仮固定し、その後、リアクトル全体をモールドしている。   Patent Document 1 discloses a reactor structure. Specifically, a spiral groove is provided on the outer peripheral portion of the hollow cylindrical bobbin, and a flat rectangular conductor is wound along the groove. Further, in order to form an elongated donut-shaped core portion, an I-type core, a U-type core, and a gap material are sequentially press-fitted into the hollow portion of the bobbin and temporarily fixed, and then the entire reactor is molded.

特開2003−124039号公報JP 2003-1224039 A

ボビンの中空部に対し各コア(I型コア、U型コア)、ギャップ材を順に圧入していかねばならず製造しにくい。また、各部品(ボビン、各コア、ギャップ材)の位置関係を保ちにくい。   Each core (I-type core, U-type core) and gap material must be pressed into the hollow portion of the bobbin in order, making it difficult to manufacture. In addition, it is difficult to maintain the positional relationship of each component (bobbin, each core, gap material).

本発明は、このような背景の下になされたものであり、その目的は、製造が容易であるとともにコアの位置決めが容易な誘導機器を提供することにある。   The present invention has been made under such a background, and an object of the present invention is to provide an induction device that is easy to manufacture and can easily position a core.

請求項1に記載の発明では、端部を有する第1のコアと、前記第1のコアにおける少なくとも端部を覆うようにモールドし、かつ、筒状部を有するモールド樹脂材と、端部を有し、当該端部が前記モールド樹脂材の筒状部に圧入され、前記第1のコアと共に閉磁路を形成する第2のコアと、前記モールド樹脂材の周囲に巻回されたコイルと、を備えたことを要旨とする。   In the first aspect of the present invention, the first core having an end portion, a mold resin material having a cylindrical portion molded so as to cover at least the end portion of the first core, and the end portion are formed. A second core that is press-fitted into the cylindrical portion of the mold resin material and forms a closed magnetic path together with the first core; and a coil wound around the mold resin material; The main point is that

請求項1に記載の発明によれば、第1のコアは、筒状部を有するモールド樹脂材によって、少なくとも端部が覆われている。また、第2のコアは、モールド樹脂材の筒状部に端部が圧入され、第1のコアと共に閉磁路を形成する。さらに、モールド樹脂材の周囲にコアが巻回されている。   According to the first aspect of the present invention, at least the end of the first core is covered with the mold resin material having the cylindrical portion. In addition, the end of the second core is press-fitted into the cylindrical portion of the mold resin material, and forms a closed magnetic path together with the first core. Furthermore, a core is wound around the mold resin material.

よって、第2のコアを筒状部に圧入すれば、第1のコアと第2のコアとで閉磁路を形成することができ、ボビンに第1のコアと第2のコアをそれぞれ圧入する場合と比べて製造が容易である。また、第1のコアの位置がモールド樹脂材によって固定されており、第2のコアをモールド樹脂材の筒状部に圧入する構成なので第1のコアと第2のコアの位置決めが容易である。   Therefore, if the second core is press-fitted into the cylindrical portion, a closed magnetic path can be formed by the first core and the second core, and the first core and the second core are respectively press-fitted into the bobbin. Manufacturing is easier than in the case. Further, since the position of the first core is fixed by the mold resin material and the second core is press-fitted into the cylindrical portion of the mold resin material, the first core and the second core can be easily positioned. .

請求項2に記載の発明では、請求項1に記載の誘導機器において、前記第1のコアの端面においてギャップ材を前記モールド樹脂材と一体成形したことを要旨とする。
請求項2に記載の発明によれば、ギャップ材は第1のコアの端面においてモールド樹脂材と一体成形されているので、ギャップ材を接着剤等でコアに接着する必要がなく、コスト低減を図ることができる。また、ギャップ材をボビンの中空部に圧入する方式に比べて製造が容易であるとともに、ギャップ材のコアに対する位置決めを容易にすることが可能となる。
The gist of the invention according to claim 2 is that, in the induction device according to claim 1, the gap material is integrally formed with the mold resin material on the end surface of the first core.
According to the second aspect of the present invention, since the gap material is integrally formed with the mold resin material at the end face of the first core, it is not necessary to bond the gap material to the core with an adhesive or the like, thereby reducing the cost. Can be planned. Further, it is easier to manufacture than the method of press-fitting the gap material into the hollow portion of the bobbin, and the gap material can be easily positioned with respect to the core.

請求項3に記載の発明では、請求項1に記載の誘導機器において、前記第1のコアおよび前記第2のコアと共に閉磁路を形成する第3のコアを備え、前記第3のコアは、前記モールド樹脂材における前記筒状部よりも前記第1のコアの端部側にモールドされた状態で配置されていることを要旨とする。   According to a third aspect of the present invention, in the induction device according to the first aspect, the induction device includes a third core that forms a closed magnetic circuit together with the first core and the second core, and the third core includes: The gist of the present invention is that the mold resin material is arranged in a state of being molded closer to the end portion side of the first core than the cylindrical portion.

請求項3に記載の発明によれば、第1のコアおよび第2のコアと共に閉磁路を形成する第3のコアはモールド樹脂材にモールドされた状態で配置されているので、第2のコアを筒状部に圧入すれば、第1のコアと第2のコアと第3のコアとで閉磁路を形成することができ、ボビンに第1のコアと第2のコアと第3のコアをそれぞれ圧入する場合と比べて製造が容易である。また、第1のコアと第3のコアの位置がモールド樹脂材によって固定されており、第2のコアをモールド樹脂材の筒状部に圧入する構成なので、第1のコアと第3のコアの位置決め及び第2のコアと第3のコアの位置決めが容易である。   According to the third aspect of the present invention, the third core that forms the closed magnetic path together with the first core and the second core is disposed in a state of being molded in the molding resin material. Can be press-fitted into the cylindrical portion, a closed magnetic path can be formed by the first core, the second core, and the third core, and the first core, the second core, and the third core can be formed on the bobbin. Is easier to manufacture than the case of press-fitting each. In addition, since the positions of the first core and the third core are fixed by the mold resin material and the second core is press-fitted into the cylindrical portion of the mold resin material, the first core and the third core The positioning of the second core and the third core is easy.

本発明によれば、製造が容易であるとともにコアの位置決めが容易な誘導機器を提供することができる。   According to the present invention, it is possible to provide a guidance device that is easy to manufacture and easy to position the core.

(a)は第1の実施形態におけるリアクトルの平面図、(b)はリアクトルの正面図、(c)はリアクトルの側面図。(A) is a top view of the reactor in 1st Embodiment, (b) is a front view of a reactor, (c) is a side view of a reactor. (a)は分解した状態でのリアクトルの一部破断平面図、(b)は(a)のA矢視図、(c)は分解した状態でのリアクトルの一部破断側面図。(A) is a partially broken plan view of the reactor in a disassembled state, (b) is a view taken in the direction of arrow A in (a), and (c) is a partially broken side view of the reactor in a disassembled state. リアクトルの分解斜視図。The exploded perspective view of a reactor. (a)は第2の実施形態におけるリアクトルの平面図、(b)はリアクトルの正面図、(c)はリアクトルの側面図。(A) is a top view of the reactor in 2nd Embodiment, (b) is a front view of a reactor, (c) is a side view of a reactor. (a)は分解した状態でのリアクトルの一部破断平面図、(b)は(a)のA矢視図、(c)は分解した状態でのリアクトルの一部破断側面図。(A) is a partially broken plan view of the reactor in a disassembled state, (b) is a view taken in the direction of arrow A in (a), and (c) is a partially broken side view of the reactor in a disassembled state. リアクトルの分解斜視図。The exploded perspective view of a reactor. (a)は第3の実施形態におけるリアクトルの平面図、(b)はリアクトルの正面図、(c)はリアクトルの側面図。(A) is a top view of the reactor in 3rd Embodiment, (b) is a front view of a reactor, (c) is a side view of a reactor. (a)は分解した状態でのリアクトルの一部破断平面図、(b)は(a)のA矢視図、(c)は分解した状態でのリアクトルの一部破断側面図。(A) is a partially broken plan view of the reactor in a disassembled state, (b) is a view taken in the direction of arrow A in (a), and (c) is a partially broken side view of the reactor in a disassembled state. リアクトルの分解斜視図。The exploded perspective view of a reactor. (a)は第4の実施形態におけるリアクトルの平面図、(b)はリアクトルの正面図、(c)はリアクトルの側面図。(A) is a top view of the reactor in 4th Embodiment, (b) is a front view of a reactor, (c) is a side view of a reactor. (a)は分解した状態でのリアクトルの一部破断平面図、(b)は(a)のA矢視図、(c)は分解した状態でのリアクトルの一部破断側面図。(A) is a partially broken plan view of the reactor in a disassembled state, (b) is a view taken in the direction of arrow A in (a), and (c) is a partially broken side view of the reactor in a disassembled state. リアクトルの分解斜視図。The exploded perspective view of a reactor. (a)は別例におけるリアクトルの平面図、(b)はリアクトルの正面図、(c)はリアクトルの側面図。(A) is a top view of the reactor in another example, (b) is a front view of the reactor, (c) is a side view of the reactor. (a)は別例における分解した状態でのリアクトルの一部破断平面図、(b)は(a)のA矢視図、(c)は分解した状態でのリアクトルの一部破断側面図。(A) is a partially broken plan view of the reactor in a disassembled state in another example, (b) is a view taken in the direction of arrow A in (a), and (c) is a partially broken side view of the reactor in a disassembled state.

(第1の実施形態)
以下、本発明を具体化した第1の実施形態を図面に従って説明する。
図1に、本実施形態の誘導機器としてのリアクトル10を示す。本実施形態のリアクトル10では、UU型コア20を用いている。UU型コア20は、第1のコアとしてのU型コア21と、第2のコアとしてのU型コア22により構成されている。UU型コア20は、環状をなし、閉磁路を形成する。また、U型コア21とU型コア22との間にギャップが形成される。
(First embodiment)
Hereinafter, a first embodiment of the present invention will be described with reference to the drawings.
In FIG. 1, the reactor 10 as a guidance apparatus of this embodiment is shown. In the reactor 10 of this embodiment, the UU type core 20 is used. The UU type core 20 includes a U type core 21 as a first core and a U type core 22 as a second core. The UU type core 20 has an annular shape and forms a closed magnetic circuit. In addition, a gap is formed between the U-shaped core 21 and the U-shaped core 22.

リアクトル10は、UU型コア20(U型コア21、U型コア22)とコイル30,31とモールド樹脂材40を備えている。また、リアクトル10は図2,3に示すコアアッシィCAを具備している。このコアアッシィCAは、U型コア21を、モールド樹脂材40によりギャップ材50,51を配した状態で一体的にモールドしたものである。そして、モールド樹脂材40に形成した筒状部46,47にU型コア22の端部22a,22bを圧入してコアアッシィCAにU型コア22を組み付けることによりリアクトル10が構成されている。   The reactor 10 includes a UU type core 20 (U type core 21 and U type core 22), coils 30 and 31, and a mold resin material 40. The reactor 10 includes a core assembly CA shown in FIGS. The core assembly CA is obtained by integrally molding the U-shaped core 21 with the gap materials 50 and 51 arranged by the mold resin material 40. The reactor 10 is configured by press-fitting the end portions 22a and 22b of the U-shaped core 22 into the cylindrical portions 46 and 47 formed in the mold resin material 40 and assembling the U-shaped core 22 to the core assembly CA.

モールド樹脂材40は、図1(a)の平面視においてU字状の本体部41と、直方体形状のステー支持部42,43,44,45を有している。
U型コア21は、断面が四角形状の棒状をなし、全体形状としてU字状をなしている。U型コア21は、直線的に延びる端部21a,21bを有し、その先端が端面21c,21dとなっている。同様に、U型コア22も、断面が四角形状の棒状をなし、全体形状としてU字状をなしている。U型コア22は、直線的に延びる端部22a,22bを有し、その先端が端面22c,22dとなっている。
The mold resin material 40 has a U-shaped main body portion 41 and a rectangular parallelepiped-shaped stay support portions 42, 43, 44, 45 in a plan view of FIG.
The U-shaped core 21 has a quadrangular bar shape in cross section, and has a U shape as a whole. The U-shaped core 21 has end portions 21a and 21b extending linearly, and the tip ends thereof are end surfaces 21c and 21d. Similarly, the U-shaped core 22 has a square bar shape in cross section, and has a U shape as a whole. The U-shaped core 22 has end portions 22a and 22b extending linearly, and tip ends thereof are end surfaces 22c and 22d.

ギャップ材50は四角板状の樹脂よりなり、U型コア21の端面21cとU型コア22の端面22cとの間に介在され、U型コア21の端面21cとU型コア22の端面22cがギャップ材50を介して突き合わされている。同様に、ギャップ材51は四角板状の樹脂よりなり、U型コア21の端面21dとU型コア22の端面22dとの間に介在され、U型コア21の端面21dとU型コア22の端面22dがギャップ材51を介して突き合わされている。樹脂製のギャップ材50,51は、モールド樹脂材40と一体成形されている。   The gap member 50 is made of a rectangular plate-like resin, and is interposed between the end surface 21 c of the U-shaped core 21 and the end surface 22 c of the U-shaped core 22, and the end surface 21 c of the U-shaped core 21 and the end surface 22 c of the U-shaped core 22 are formed. It is abutted via the gap material 50. Similarly, the gap member 51 is made of a square plate-like resin, and is interposed between the end surface 21 d of the U-shaped core 21 and the end surface 22 d of the U-shaped core 22, and the gap between the end surface 21 d of the U-shaped core 21 and the U-shaped core 22. The end face 22d is abutted through the gap material 51. The resin gap members 50 and 51 are integrally formed with the mold resin material 40.

モールド樹脂材40の本体部41は、U型コア21の全域を覆うようにモールドし、かつ、筒状部46,47を有している。筒状部46,47は、四角筒状をなし、U型コア21の端部21a,21bの外周の部位からU型コア22の端部22a,22bに向かって直線的に延びている。筒状部46,47の内形はU型コア22の端部22a,22bの外形よりも若干小さく、筒状部46,47の内部にU型コア22の端部22a,22bを圧入することができるようになっている。   The main body portion 41 of the molded resin material 40 is molded so as to cover the entire area of the U-shaped core 21 and has cylindrical portions 46 and 47. The cylindrical portions 46 and 47 have a rectangular cylindrical shape and linearly extend from the outer peripheral portions of the end portions 21 a and 21 b of the U-shaped core 21 toward the end portions 22 a and 22 b of the U-shaped core 22. The inner shape of the cylindrical portions 46 and 47 is slightly smaller than the outer shape of the end portions 22a and 22b of the U-shaped core 22, and the end portions 22a and 22b of the U-shaped core 22 are press-fitted into the cylindrical portions 46 and 47. Can be done.

図1(a)においてステー支持部42,43は本体部41の右側面に離間して形成される。また、ステー支持部44,45は本体部41の左側面に離間して形成されている。各ステー支持部42,43,44,45にはL字の金属板よりなるステー70の一端が埋設されている。固定部材としてのステー70は各ステー支持部42,43,44,45の下面から下方に突出し、下端から水平方向に延びている。ステー70の他端にはボルト孔(貫通孔)71が形成され、ボルトをボルト孔71を通してケース(図示略)側に螺入することによりケースにリアクトル10を固定することができるようになっている。   In FIG. 1A, the stay support portions 42 and 43 are formed on the right side surface of the main body portion 41 so as to be separated from each other. The stay support portions 44 and 45 are formed on the left side surface of the main body portion 41 so as to be separated from each other. One end of a stay 70 made of an L-shaped metal plate is embedded in each stay support portion 42, 43, 44, 45. The stay 70 as a fixing member protrudes downward from the lower surface of each of the stay support portions 42, 43, 44, 45 and extends in the horizontal direction from the lower end. A bolt hole (through hole) 71 is formed at the other end of the stay 70, and the reactor 10 can be fixed to the case by screwing the bolt into the case (not shown) through the bolt hole 71. Yes.

コイル30はモールド樹脂材40の本体部41におけるU型コア21とU型コア22との2つの連結部のうちの一方の連結部の周囲に巻回されている。一方、コイル31は、モールド樹脂材40の本体部41におけるU型コア21とU型コア22との2つの連結部のうちの他方の連結部の周囲に巻回されている。コイル30,31はモールド樹脂材40に一体化されている。   The coil 30 is wound around one of the two connecting portions of the U-shaped core 21 and the U-shaped core 22 in the main body 41 of the molded resin material 40. On the other hand, the coil 31 is wound around the other connecting portion of the two connecting portions of the U-shaped core 21 and the U-shaped core 22 in the main body portion 41 of the molded resin material 40. The coils 30 and 31 are integrated with the mold resin material 40.

次に、リアクトル10の組み立て工程について説明する。
まず、コアアッシィCAとU型コア22を用意する。
図2,3のコアアッシィCAにおいて、U型コア21はモールド樹脂材40にモールドされている。また、モールド樹脂材40における筒状部46,47の奥においてU型コア21の端面21c,21dにギャップ材50,51が一体成形されている。さらに、モールド樹脂材40にコイル30,31が一体化されている。
Next, the assembly process of the reactor 10 will be described.
First, the core assembly CA and the U-shaped core 22 are prepared.
2 and 3, the U-shaped core 21 is molded in a molded resin material 40. In addition, gap members 50 and 51 are integrally formed on the end surfaces 21 c and 21 d of the U-shaped core 21 in the back of the cylindrical portions 46 and 47 in the mold resin material 40. Further, the coils 30 and 31 are integrated with the mold resin material 40.

引き続き、コアアッシィCAにおけるモールド樹脂材40の筒状部46,47にU型コア22の端部22a,22bを圧入し、図1に示すように、ギャップ材50,51をU型コア21の端面21c,21dとU型コア22の端面22c,22dとの間に挟み込む。   Subsequently, the end portions 22a and 22b of the U-shaped core 22 are press-fitted into the cylindrical portions 46 and 47 of the mold resin material 40 in the core assembly CA, and the gap materials 50 and 51 are inserted into the end surfaces of the U-shaped core 21 as shown in FIG. 21c and 21d are sandwiched between the end faces 22c and 22d of the U-shaped core 22.

これにより、モールド樹脂材40の筒状部46,47の内面にU型コア22の端部22a,22bの外面が接触した状態でU型コア21,22が位置決めされる。このとき、モールド樹脂材40の本体部41により、U型コア21とU型コア22とが連結支持される。よって、モールド樹脂材40の本体部41がU型コア21とU型コア22とを連結支持するときの梁部として機能する。   Thereby, the U-shaped cores 21 and 22 are positioned in a state where the outer surfaces of the end portions 22a and 22b of the U-shaped core 22 are in contact with the inner surfaces of the cylindrical portions 46 and 47 of the mold resin material 40. At this time, the U-shaped core 21 and the U-shaped core 22 are connected and supported by the main body 41 of the molded resin material 40. Therefore, the main body portion 41 of the mold resin material 40 functions as a beam portion when the U-shaped core 21 and the U-shaped core 22 are connected and supported.

そして、ボルトをステー70のボルト孔71を通してケース(図示略)のねじ孔に螺入することによりリアクトル10をケースに固定する。よって、モールド樹脂材40に一体的に設けたステー70を用いてリアクトル10をケースに締結でき、別部材を用いてリアクトルを固定する場合に比べ取付が容易である。   Then, the reactor 10 is fixed to the case by screwing the bolt into the screw hole of the case (not shown) through the bolt hole 71 of the stay 70. Therefore, the reactor 10 can be fastened to the case using the stay 70 provided integrally with the mold resin material 40, and attachment is easier than when the reactor is fixed using another member.

また、U型コア21とU型コア22との間のギャップ材50,51によるギャップ部においてモールド樹脂材40による梁構造が構築されている。これにより、ギャップ材を単にU型コアの端面に接着する場合に比べて、ギャップ部の剛性が向上する。その結果、リアクトル10の使用時にU型コア21,22間に働く繰り返し応力(吸引力)による変形を抑え、NV(Noise and Vibration)を抑制することができる。   Further, a beam structure made of the mold resin material 40 is constructed in the gap portion formed by the gap materials 50 and 51 between the U-shaped core 21 and the U-shaped core 22. Thereby, the rigidity of a gap part improves compared with the case where a gap material is simply adhere | attached on the end surface of a U-shaped core. As a result, deformation due to repetitive stress (suction force) acting between the U-shaped cores 21 and 22 when the reactor 10 is used can be suppressed, and NV (Noise and Vibration) can be suppressed.

さらに、U型コア21,22とコイル30,31とギャップ材50,51について、厳密な位置決めを行うことができる。その結果、コイル損失やL値のばらつきを低減することができる。   Furthermore, the U-shaped cores 21 and 22, the coils 30 and 31, and the gap members 50 and 51 can be strictly positioned. As a result, coil loss and variation in L value can be reduced.

以上のごとく本実施形態によれば、以下のような効果を得ることができる。
(1)第1のコアとしてのU型コア21はモールド樹脂材40によりモールドされ(広義には、U型コア21における少なくとも端部21a,21bを覆うようにモールドされ)、モールド樹脂材40は筒状部46,47を有している。第2のコアとしてのU型コア22は、端部22a,22bがモールド樹脂材40の筒状部46,47に圧入され、U型コア21と共に閉磁路を形成する。また、コイル30,31がモールド樹脂材40の周囲に巻回されている。
As described above, according to the present embodiment, the following effects can be obtained.
(1) The U-shaped core 21 as the first core is molded with a molded resin material 40 (in a broad sense, molded so as to cover at least the end portions 21a and 21b of the U-shaped core 21). Cylindrical portions 46 and 47 are provided. The U-shaped core 22 as the second core has its end portions 22 a and 22 b press-fitted into the cylindrical portions 46 and 47 of the molded resin material 40, and forms a closed magnetic path together with the U-shaped core 21. The coils 30 and 31 are wound around the mold resin material 40.

よって、U型コア22を筒状部46,47に圧入すれば、U型コア21とU型コア22とで閉磁路を形成することができ、ボビンにU型コア21,22をそれぞれ圧入する場合と比べて製造が容易である。また、U型コア21の位置がモールド樹脂材40によって固定されており、U型コア22をモールド樹脂材40の筒状部46,47に圧入する構成なので、U型コア21とU型コア22の位置決めが容易である。その結果、製造が容易であるとともにコアの位置決めが容易なリアクトルを提供することができる。   Therefore, if the U-shaped core 22 is press-fitted into the cylindrical portions 46 and 47, a closed magnetic path can be formed by the U-shaped core 21 and the U-shaped core 22, and the U-shaped cores 21 and 22 are pressed into the bobbins, respectively. Manufacturing is easier than in the case. Further, since the position of the U-shaped core 21 is fixed by the mold resin material 40 and the U-shaped core 22 is press-fitted into the cylindrical portions 46 and 47 of the molded resin material 40, the U-shaped core 21 and the U-shaped core 22. Is easy to position. As a result, it is possible to provide a reactor that is easy to manufacture and easy to position the core.

(2)U型コア21の端面21c,21dにおいてギャップ材50,51をモールド樹脂材40と一体成形したので、ギャップ材50,51を接着剤等でU型コア21またはU型コア22に接着する必要がなく、コスト低減を図ることが可能となる。また、ギャップ材50,51をボビンの中空部に圧入する方式に比べて製造が容易であるとともに、ギャップ材50,51のU型コア21,22に対する位置決めを容易にすることが可能となる。   (2) Since the gap members 50 and 51 are integrally formed with the mold resin material 40 on the end faces 21c and 21d of the U-shaped core 21, the gap members 50 and 51 are bonded to the U-shaped core 21 or the U-shaped core 22 with an adhesive or the like. Therefore, it is possible to reduce the cost. Further, it is easier to manufacture than the method of press-fitting the gap members 50 and 51 into the hollow portion of the bobbin, and the positioning of the gap members 50 and 51 with respect to the U-shaped cores 21 and 22 can be facilitated.

なお、樹脂製のギャップ材50,51に代わり、セラミック等の樹脂以外の材料のギャップ材をモールド樹脂材40と一体成形してもよい。
(第2の実施形態)
次に、第2の実施形態を、第1の実施形態との相違点を中心に説明する。
Instead of the resin gap materials 50 and 51, a gap material other than a resin such as ceramic may be integrally formed with the mold resin material 40.
(Second Embodiment)
Next, the second embodiment will be described focusing on the differences from the first embodiment.

図4,5,6には、本実施形態におけるリアクトル11を示す。
第1の実施形態では、ギャップ材50,51をモールド樹脂材40と一体化した。これに対し、本実施形態においては、モールド樹脂材40とは別体のセラミック製ギャップ板80,81を用いている。
4, 5 and 6 show the reactor 11 in the present embodiment.
In the first embodiment, the gap members 50 and 51 are integrated with the mold resin member 40. On the other hand, in the present embodiment, ceramic gap plates 80 and 81 that are separate from the mold resin material 40 are used.

図5,6に示すように、コアアッシィCAにおいて、U型コア21はモールド樹脂材40により端面21c,21dが露出する状態でモールドされている。
U型コア22の組み付け前の状態において、U型コア22の端面21cにはセラミック製ギャップ板80の一方の面が接着剤82により貼り付けられている。また、セラミック製ギャップ板80の他方の面には接着剤83が塗布されている。同様に、U型コア22の端面21dにはセラミック製ギャップ板81の一方の面が接着剤84により貼り付けられている。また、セラミック製ギャップ板81の他方の面には接着剤85が塗布されている。
As shown in FIGS. 5 and 6, in the core assembly CA, the U-shaped core 21 is molded with the mold resin material 40 with the end faces 21 c and 21 d exposed.
Before the U-shaped core 22 is assembled, one surface of the ceramic gap plate 80 is adhered to the end surface 21 c of the U-shaped core 22 with an adhesive 82. An adhesive 83 is applied to the other surface of the ceramic gap plate 80. Similarly, one surface of the ceramic gap plate 81 is attached to the end surface 21 d of the U-shaped core 22 with an adhesive 84. An adhesive 85 is applied to the other surface of the ceramic gap plate 81.

そして、図4に示すように、コアアッシィCAにおけるモールド樹脂材40の筒状部46,47にU型コア22の端部22a,22bを圧入し、セラミック製ギャップ板80,81をU型コア21の端面21c,21d(図5参照)とU型コア22の端面22c,22d(図5参照)との間に挟み込む。これにより、セラミック製ギャップ板80,81がU型コア21の端面21c,21dに接着剤83,85により接着される。   Then, as shown in FIG. 4, the end portions 22 a and 22 b of the U-shaped core 22 are press-fitted into the cylindrical portions 46 and 47 of the mold resin material 40 in the core assembly CA, and the ceramic gap plates 80 and 81 are inserted into the U-shaped core 21. Are sandwiched between the end faces 21c and 21d (see FIG. 5) and the end faces 22c and 22d (see FIG. 5) of the U-shaped core 22. As a result, the ceramic gap plates 80 and 81 are bonded to the end faces 21 c and 21 d of the U-shaped core 21 by the adhesives 83 and 85.

このように本実施形態のリアクトル11では、U型コア21,22の端面21c,21d,22c,22dにギャップ材としてのセラミック製ギャップ板80,81を接着した。よって、接着にてU型コア21,22の端面21c,21d,22c,22dにセラミック製ギャップ板80,81を固定することができる。
(第3の実施形態)
次に、第3の実施形態を、第1の実施形態との相違点を中心に説明する。
As described above, in the reactor 11 of the present embodiment, the ceramic gap plates 80 and 81 as the gap material are bonded to the end faces 21c, 21d, 22c, and 22d of the U-shaped cores 21 and 22, respectively. Therefore, the ceramic gap plates 80 and 81 can be fixed to the end faces 21c, 21d, 22c and 22d of the U-shaped cores 21 and 22 by bonding.
(Third embodiment)
Next, the third embodiment will be described focusing on the differences from the first embodiment.

図7,8,9には、本実施形態におけるリアクトル12を示す。なお、図9においてはコイル30,31は省略している。
第1の実施形態では、樹脂製のギャップ材50,51を用いた。これに対し、本実施形態においては、エアギャップAGを用いている。
7, 8 and 9 show the reactor 12 in the present embodiment. In FIG. 9, the coils 30 and 31 are omitted.
In the first embodiment, resin gap members 50 and 51 are used. On the other hand, in this embodiment, an air gap AG is used.

図8,9に示すように、コアアッシィCAのモールド樹脂材40において、U型コア21の端面21cに相当する部位、即ち、ギャップ形成部には一対のエアギャップ形成用突起90,91が形成されている。エアギャップ形成用突起90,91は上下方向に延びている。同様に、コアアッシィCAのモールド樹脂材40において、U型コア21の端面21dに相当する部位、即ち、ギャップ形成部には一対のエアギャップ形成用突起92,93が形成されている。エアギャップ形成用突起92,93は上下方向に延びている。   8 and 9, in the mold resin material 40 of the core assembly CA, a pair of air gap forming projections 90 and 91 are formed in a portion corresponding to the end surface 21c of the U-shaped core 21, that is, the gap forming portion. ing. The air gap forming protrusions 90 and 91 extend in the vertical direction. Similarly, in the mold resin material 40 of the core assembly CA, a pair of air gap forming projections 92 and 93 are formed in a portion corresponding to the end surface 21d of the U-shaped core 21, that is, the gap forming portion. The air gap forming protrusions 92 and 93 extend in the vertical direction.

U型コア22の組み付け前の状態において、コアアッシィCAのモールド樹脂材40でのU型コア21の端面21cにはエアギャップ形成用突起90,91がモールド樹脂材40と一体成形されているとともに、U型コア21の端面21dにはエアギャップ形成用突起92,93がモールド樹脂材40と一体成形されている。   In the state before the U-shaped core 22 is assembled, air gap forming protrusions 90 and 91 are integrally formed with the molded resin material 40 on the end surface 21c of the U-shaped core 21 of the molded resin material 40 of the core assembly CA. Air gap forming protrusions 92 and 93 are integrally formed with the mold resin material 40 on the end surface 21 d of the U-shaped core 21.

そして、コアアッシィCAにおけるモールド樹脂材40の筒状部46,47にU型コア22の端部22a,22bを圧入する。これにより、図7に示すように、エアギャップ形成用突起90,91がU型コア21の端面21cとU型コア22の端面22cとの間に挟み込まれ、U型コア21の端面21cとU型コア22の端面22cとの間にエアギャップAGが形成される。同様に、エアギャップ形成用突起92,93がU型コア21の端面21dとU型コア22の端面22dとの間に挟み込まれ、U型コア21の端面21dとU型コア22の端面22dとの間にエアギャップAGが形成される。   Then, the end portions 22a and 22b of the U-shaped core 22 are press-fitted into the cylindrical portions 46 and 47 of the mold resin material 40 in the core assembly CA. As a result, as shown in FIG. 7, the air gap forming protrusions 90 and 91 are sandwiched between the end surface 21 c of the U-shaped core 21 and the end surface 22 c of the U-shaped core 22. An air gap AG is formed between the end surface 22 c of the mold core 22. Similarly, air gap forming projections 92 and 93 are sandwiched between the end surface 21 d of the U-shaped core 21 and the end surface 22 d of the U-shaped core 22, and the end surface 21 d of the U-shaped core 21 and the end surface 22 d of the U-shaped core 22 are An air gap AG is formed between the two.

このように本実施形態のリアクトル12では、U型コア21の端面21c,21dにおいてエアギャップ形成用突起90,91,92,93をモールド樹脂材40と一体成形し、U型コア21の端面21c,21dとU型コア22の端面22c,22dの間にエアギャップAGを形成した。よって、接着剤なしにギャップを形成することができる。また、エアギャップ(エアギャップ形成用突起90,91,92,93)のモールド樹脂材40に対する位置決めが容易である。
(第4の実施形態)
次に、第4の実施形態を、第1,2,3の実施形態との相違点を中心に説明する。
As described above, in the reactor 12 of the present embodiment, the air gap forming protrusions 90, 91, 92, 93 are integrally formed with the mold resin material 40 on the end surfaces 21 c, 21 d of the U-shaped core 21, and the end surface 21 c of the U-shaped core 21 is formed. , 21d and the end faces 22c, 22d of the U-shaped core 22 are formed with air gaps AG. Therefore, a gap can be formed without an adhesive. Further, the air gap (air gap forming protrusions 90, 91, 92, 93) can be easily positioned with respect to the mold resin material 40.
(Fourth embodiment)
Next, the fourth embodiment will be described focusing on differences from the first, second, and third embodiments.

図10,11,12には、本実施形態におけるリアクトル13を示す。なお、図12においてはコイル30,31は省略している。また、本実施形態ではコアアッシィCA(モールド樹脂材40)に固定部材としてのステーは設けていない。   10, 11 and 12 show a reactor 13 in the present embodiment. In FIG. 12, the coils 30 and 31 are omitted. In this embodiment, the stay as a fixing member is not provided in the core assembly CA (molded resin material 40).

本実施形態においては、U−I−U型のコア100を用いている。詳しくは、コア100は、第1のコアとしてのU型コア101と、第2のコアとしてのU型コア102と、第3のコアとしてのI型コア103、I型コア104、I型コア105およびI型コア106からなる。U型コア101の一方の端面101cから、順に、I型コア103、I型コア104、U型コア102の一方の端面102cが配置されている。また、U型コア101の他方の端面101dから、順に、I型コア105、I型コア106、U型コア102の他方の端面102dが配置されている。U型コア101、I型コア103、I型コア104、I型コア105、I型コア106はモールド樹脂材40によりモールドされている。   In this embodiment, a U-I-U type core 100 is used. Specifically, the core 100 includes a U-type core 101 as a first core, a U-type core 102 as a second core, an I-type core 103, an I-type core 104, and an I-type core as third cores. 105 and an I-type core 106. From one end surface 101 c of the U-shaped core 101, an I-type core 103, an I-type core 104, and one end surface 102 c of the U-shaped core 102 are disposed in order. In addition, the I-type core 105, the I-type core 106, and the other end face 102d of the U-type core 102 are arranged in this order from the other end face 101d of the U-type core 101. The U-type core 101, the I-type core 103, the I-type core 104, the I-type core 105, and the I-type core 106 are molded with a mold resin material 40.

また、U型コア101の一方の端面101cとI型コア103との間には樹脂製のギャップ材107が配置され、I型コア103とI型コア104との間には樹脂製のギャップ材108が配置され、I型コア104とU型コア102の一方の端面102cとの間には樹脂製のギャップ材109が配置されている。さらに、U型コア101の他方の端面101dとI型コア105との間には樹脂製のギャップ材110が配置され、I型コア105とI型コア106との間には樹脂製のギャップ材111が配置され、I型コア106とU型コア102の他方の端面102dとの間には樹脂製のギャップ材112が配置されている。樹脂製のギャップ材107,108,109,110,111,112は、モールド樹脂材40と一体成形されている。   A resin gap material 107 is disposed between one end face 101 c of the U-shaped core 101 and the I-type core 103, and a resin-made gap material is disposed between the I-type core 103 and the I-type core 104. 108 is disposed, and a resin gap material 109 is disposed between the I-type core 104 and one end face 102 c of the U-type core 102. Further, a resin gap material 110 is disposed between the other end face 101 d of the U-type core 101 and the I-type core 105, and a resin-made gap material is provided between the I-type core 105 and the I-type core 106. 111 is disposed, and a resin gap material 112 is disposed between the I-type core 106 and the other end face 102 d of the U-type core 102. The resin gap members 107, 108, 109, 110, 111, and 112 are integrally formed with the mold resin material 40.

なお、樹脂製のギャップ材107,108,109,110,111,112に代わり、セラミック等の樹脂以外の材料のギャップ材を用いてもよい。
図11,12に示すU型コア102の組み付け前の状態では、コアアッシィCAにおいて、U型コア101とI型コア103とI型コア104とI型コア105とI型コア106とがモールド樹脂材40により位置決めした状態でモールドされている。また、樹脂製のギャップ材107,108,109,110,111,112がモールド樹脂材40と一体成形されている。
Instead of the resin gap materials 107, 108, 109, 110, 111, and 112, a gap material made of a material other than resin such as ceramic may be used.
11 and 12, before the assembly of the U-shaped core 102, in the core assembly CA, the U-shaped core 101, the I-shaped core 103, the I-shaped core 104, the I-shaped core 105, and the I-shaped core 106 are molded resin materials. Molded in a state of being positioned by 40. In addition, resin gap members 107, 108, 109, 110, 111, and 112 are integrally formed with the mold resin material 40.

そして、コアアッシィCAにおけるモールド樹脂材40の筒状部46,47にU型コア102の端部102a,102bを圧入し、図10に示すように、ギャップ材109,112をU型コア102の端面102c,102dとI型コア104,106との間に挟み込む。   Then, the end portions 102a and 102b of the U-shaped core 102 are press-fitted into the cylindrical portions 46 and 47 of the mold resin material 40 in the core assembly CA, and the gap materials 109 and 112 are inserted into the end surfaces of the U-shaped core 102 as shown in FIG. It is sandwiched between 102c and 102d and the I-type cores 104 and 106.

このように本実施形態のリアクトル13では、第1のコアおよび第2のコアと共に閉磁路を形成する第3のコアとしてのI型コア103,104,105,106を備えている。このI型コア103,104,105,106は、モールド樹脂材40における筒状部46,47よりもU型コア101(第1のコア)の端部101a,101b側にモールドされた状態で配置されている。よって、U型コア102を筒状部46,47に圧入すれば、U型コア101とU型コア102とI型コア103,104,105,106とで閉磁路を形成することができ、ボビンにU型コア101とU型コア102とI型コア103,104,105,106をそれぞれ圧入する場合と比べて製造が容易である。また、U型コア101とI型コア103,104,105,106の位置がモールド樹脂材40によって固定されており、U型コア102をモールド樹脂材40の筒状部46,47に圧入する構成なので、U型コア101とI型コア103,104,105,106の位置決め及びU型コア102とI型コア103,104,105,106の位置決めを容易にすることが可能となる。   As described above, the reactor 13 according to the present embodiment includes the I-type cores 103, 104, 105, and 106 as the third core that forms a closed magnetic circuit together with the first core and the second core. The I-type cores 103, 104, 105, and 106 are arranged in a state of being molded closer to the end portions 101a and 101b of the U-type core 101 (first core) than the cylindrical portions 46 and 47 in the molded resin material 40. Has been. Therefore, if the U-shaped core 102 is press-fitted into the cylindrical portions 46 and 47, a closed magnetic path can be formed by the U-shaped core 101, the U-shaped core 102, and the I-shaped cores 103, 104, 105, and 106. Compared with the case where the U-shaped core 101, the U-shaped core 102, and the I-shaped cores 103, 104, 105, and 106 are respectively press-fitted, manufacturing is easier. Further, the positions of the U-shaped core 101 and the I-shaped cores 103, 104, 105, 106 are fixed by the mold resin material 40, and the U-shaped core 102 is press-fitted into the cylindrical portions 46, 47 of the mold resin material 40. Therefore, it is possible to facilitate positioning of the U-type core 101 and the I-type cores 103, 104, 105, and 106 and positioning of the U-type core 102 and the I-type cores 103, 104, 105, and 106.

なお、図10,11,12では4つのI型コア103,104,105,106を用いたが、I型コアの数は4つ以外でもよく、例えば、2つのI型コアを用いても6つ以上のI型コアを用いてもよい。   10, 11, and 12 use four I-type cores 103, 104, 105, and 106, the number of I-type cores may be other than four. For example, even if two I-type cores are used, 6 Two or more type I cores may be used.

実施形態は前記に限定されるものではなく、例えば、次のように具体化してもよい。
・第1のコアとしてのU型コア21,101は、モールド樹脂材40により全域を覆うようにモールドしたが、U型コア21,101における少なくとも端部21a,21b,101a,101bを覆うようにモールドすればよい。
The embodiment is not limited to the above, and may be embodied as follows, for example.
The U-shaped cores 21 and 101 as the first core are molded so as to cover the entire area with the molding resin material 40, but at least the end portions 21a, 21b, 101a and 101b of the U-shaped cores 21 and 101 are covered. What is necessary is just to mold.

・コイル30,31はコアアッシィCAに一体的に設けたが(モールド樹脂材40に一体化したが)、コイル30,31はコアアッシィCA(モールド樹脂材40)とは別体とし、コアアッシィCA(モールド樹脂材40)に後付けしてもよい。   Although the coils 30 and 31 are provided integrally with the core assembly CA (although integrated with the mold resin material 40), the coils 30 and 31 are separated from the core assembly CA (mold resin material 40), and the core assembly CA (mold) It may be retrofitted to the resin material 40).

・第1,第2,第3の実施形態において固定部材としてのステー70はコアアッシィCAに一体的に設けたが(モールド樹脂材40に一体化したが)、固定部材はコアアッシィCA(モールド樹脂材40)とは別体とし、コアアッシィCA(モールド樹脂材40)に後付けしてもよい。   In the first, second, and third embodiments, the stay 70 as a fixing member is provided integrally with the core assembly CA (although integrated with the mold resin material 40), but the fixing member is the core assembly CA (mold resin material). 40) and may be retrofitted to the core assembly CA (molded resin material 40).

・図13に示すように、樹脂材120でモールドされた第2のコアとしてのU型コア22をモールド樹脂材40の筒状部46,47に圧入してもよい。即ち、図14に示すように、U型コア22における露出部を樹脂材120でモールドしておき、この樹脂モールドされたU型コア22をモールド樹脂材40の筒状部46,47に圧入する。この構成によれば、ボビンの中空部にU型コア21,22を圧入したものを樹脂モールドする構成に比べ第1のコアとしてのU型コア21のモールド樹脂材40がボビンの機能を兼務するので、コスト低減が可能となる。また、図13,14に代わり、第2のコアとしてのU型コア22の全域を樹脂モールドしてモールド樹脂材40の筒状部46,47に圧入してもよい。   As shown in FIG. 13, the U-shaped core 22 as the second core molded with the resin material 120 may be press-fitted into the cylindrical portions 46 and 47 of the molded resin material 40. That is, as shown in FIG. 14, the exposed portion of the U-shaped core 22 is molded with the resin material 120, and the resin-molded U-shaped core 22 is press-fitted into the cylindrical portions 46 and 47 of the molded resin material 40. . According to this configuration, the mold resin material 40 of the U-shaped core 21 as the first core also serves as the bobbin, compared to a configuration in which the U-shaped cores 21 and 22 are press-fitted into the hollow portion of the bobbin. Therefore, the cost can be reduced. 13 and 14, the entire region of the U-shaped core 22 as the second core may be resin-molded and press-fitted into the cylindrical portions 46 and 47 of the molded resin material 40.

・誘導機器はリアクトルに限ることなく、他にも、例えばトランスであってもよい。   The induction device is not limited to a reactor, and may be a transformer, for example.

21…U型コア、21a…端部、21b…端部、21c…端面、21d…端面、22…U型コア、22a…端部、22b…端部、30…コイル、31…コイル、40…モールド樹脂材、46…筒状部、47…筒状部、50…ギャップ材、51…ギャップ材、101…U型コア、101a…端部、101b…端部、102…U型コア、102a…端部、102b…端部、103…I型コア、104…I型コア、105…I型コア、106…I型コア。   21 ... U-shaped core, 21a ... end, 21b ... end, 21c ... end, 21d ... end, 22 ... U-shaped core, 22a ... end, 22b ... end, 30 ... coil, 31 ... coil, 40 ... Mold resin material 46 ... Cylinder part 47 ... Cylinder part 50 ... Gap material 51 ... Gap material 101 ... U-shaped core 101a ... End part 101b ... End part 102 ... U-shaped core 102a ... End part 102b ... End part 103 ... I type core 104 ... I type core 105 ... I type core 106 ... I type core

Claims (3)

端部を有する第1のコアと、
前記第1のコアにおける少なくとも端部を覆うようにモールドし、かつ、筒状部を有するモールド樹脂材と、
端部を有し、当該端部が前記モールド樹脂材の筒状部に圧入され、前記第1のコアと共に閉磁路を形成する第2のコアと、
前記モールド樹脂材の周囲に巻回されたコイルと、
を備えたことを特徴とする誘導機器。
A first core having an end;
Molded so as to cover at least the end portion of the first core, and a mold resin material having a cylindrical portion,
A second core having an end, the end is press-fitted into the cylindrical portion of the mold resin material, and forms a closed magnetic path together with the first core;
A coil wound around the mold resin material;
An induction device characterized by comprising:
前記第1のコアの端面においてギャップ材を前記モールド樹脂材と一体成形したことを特徴とする請求項1に記載の誘導機器。   The induction device according to claim 1, wherein a gap material is integrally formed with the mold resin material on an end surface of the first core. 前記第1のコアおよび前記第2のコアと共に閉磁路を形成する第3のコアを備え、前記第3のコアは、前記モールド樹脂材における前記筒状部よりも前記第1のコアの端部側にモールドされた状態で配置されていることを特徴とする請求項1に記載の誘導機器。   A third core that forms a closed magnetic path together with the first core and the second core is provided, and the third core is an end portion of the first core rather than the cylindrical portion of the mold resin material. The induction device according to claim 1, wherein the induction device is arranged in a molded state on the side.
JP2010166088A 2010-07-23 2010-07-23 Induction device Pending JP2012028572A (en)

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