JP2012109296A - Coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain predetermined inductance characteristics, regardless the variation of a shape of a C-shaped core piece, in a coil device in which the C-shaped core piece and a rectangular parallelepiped core piece are combined.SOLUTION: A coil device is configured by winding a coil around an annular core. The core comprises a pair of C-shaped core pieces 2 made by dividing an annular winding core member produced by winding a metallic band plate, a rectangular parallelepiped core piece 3 interposed between the pair of the C-shaped core pieces 2, and a magnetic gap portion interposed between the opposite surfaces of the C-shaped core piece 2 and the rectangular parallelepiped core piece 3. Either one of the end surface of the C-shaped core piece 2 and the end surface of the rectangular parallelepiped core piece 3, facing to each other with the magnetic gap portion interposed therebetween, has a shape expanding a shape of the other end surface.

Description

  The present invention relates to a coil device that constitutes a reactor, a transformer, and the like in various AC devices, and more particularly to a coil device that is formed by winding a coil around an annular core.

  Conventionally, in this type of coil device, one using a laminated core is known. The laminated core includes, for example, a pair of C-shaped core pieces obtained by dividing an annular wound core member produced by winding a metal strip, and a cut surface of the pair of C-shaped core pieces. It is composed of at least two laminated rectangular parallelepiped core pieces interposed therebetween, and at least four magnetic gap portions interposed between facing surfaces of the C-shaped core piece and the rectangular parallelepiped core piece (see Patent Document 1). .

  In the above coil device, since the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece are opposed to each other via the magnetic gap portion, a leakage magnetic flux is generated in the magnetic gap portion. The inductance characteristics are determined by the thickness of the part (gap length) and the opposing areas of both end faces.

  Therefore, the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece are formed in the same shape having the same area, and both end faces are abutted with each other accurately.

Japanese Patent Laid-Open No. 11-40434

  However, in the coil device in which the C-shaped core piece and the rectangular parallelepiped core piece are combined, the C-shaped core piece is produced by dividing an annular wound core member produced by winding a metal strip. Therefore, a certain amount of variation occurs in the shape of the C-shaped core piece, which causes an error in the relative position of the two end faces of the C-shaped core piece.

  As a result, when the coil device is assembled by abutting the C-shaped core piece and the rectangular parallelepiped core piece with each other, a displacement occurs between the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece. There is a problem that the opposing area of both end faces is smaller than the area of any end face, and the desired inductance characteristics cannot be obtained.

  SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a coil device that combines a C-shaped core piece and a rectangular parallelepiped core piece, and can obtain desired inductance characteristics regardless of variations in the shape of the C-shaped core piece. Is to provide.

The coil device according to the present invention is configured by winding a coil around an annular core, and the core is a pair of parts formed by dividing an annular wound core member produced by winding a metal strip. A C-shaped core piece, a rectangular parallelepiped core piece interposed between the pair of C-shaped core pieces, and a magnetic gap portion interposed between facing surfaces of the C-shaped core piece and the rectangular parallelepiped core piece, Either one of the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece facing each other through the magnetic gap portion has a shape obtained by enlarging the shape of the other end face.
For example, any one of the end faces has a shape obtained by enlarging the shape of the other end face from the center thereof in four directions.
Or the end surface of a rectangular parallelepiped core piece has the shape which expanded the shape of the end surface of a C-shaped core piece in the winding thickness direction of the C-shaped core piece.

  According to the coil device according to the present invention, one of the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece has a shape obtained by enlarging the shape of the other end face. Even if there is some variation in the shape of the C-shaped core piece, the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece face each other, and the other end face is the contour of the one end face. It is possible to adjust the relative position of both cores so that they are within the shape, so that the opposing area between the end face of the C-shaped core piece and the end face of the rectangular parallelepiped core piece is exactly the same as the area of the other end face. Will match.

  According to the coil device according to the present invention, the facing area between the end surface of the C-shaped core piece and the end surface of the rectangular parallelepiped core piece is set to a predetermined size regardless of variations in the shape of the C-shaped core piece. As a result, the desired inductance characteristics can be obtained.

FIG. 1 is a perspective view of a coil device according to the present invention. FIG. 2 is a partially broken plan view of the coil device. FIG. 3 is a cross-sectional view of a bobbin incorporating a rectangular parallelepiped core piece. FIG. 4 is a perspective view showing a process of holding the rectangular parallelepiped core piece on the boat member. FIG. 5 is a perspective view of a bobbin incorporating a rectangular parallelepiped core piece. FIG. 6 is a cross-sectional view of a portion where the C-shaped core piece is inserted into the bobbin. FIG. 7 is a plan view showing a manufacturing process of the C-shaped core piece. FIG. 8 is a perspective view showing a manufacturing process of a rectangular parallelepiped core piece.

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
As shown in FIG. 1, the coil device according to the present invention is configured by mounting a pair of coil assemblies (5) and (5) on an annular core (1), and each coil assembly (5) has a rectangular tube shape. It consists of a bobbin (8) and a coil (7) wound around the outer peripheral surface of the bobbin (8). The core (1) extends annularly through the two bobbins (8), (8).

The two coils (7) and (7) constituting the two coil assemblies (5) and (5) are formed by winding one conductive wire, and both the coils (7) and (7) are connected to the connecting wire (72 ) Are connected to each other. From both the coils (7) and (7), a winding start end portion (71) and a winding end end portion (73) of the conducting wire are drawn out.
As shown in FIG. 2, the core (1) is composed of a pair of C-shaped core pieces (2) (2) and two rectangular parallelepiped core pieces interposed between the two C-shaped core pieces (2) (2). (3) and (3).

In the production of the pair of C-shaped core pieces (2) and (2), as shown in FIG. 7 (a), an annular wound core member (21 ) Is cut along a single cutting line AA indicated by a broken line in the drawing, thereby forming a pair of left and right C-characters as shown in FIG. The segmented core pieces (2) and (2) are obtained.
Further, the rectangular parallelepiped core piece (3) is formed by laminating a plurality of rectangular metal plates (31) made of a silicon steel plate or an amorphous material as shown in FIG.

  Here, the rectangular parallelepiped core piece (3) has a shape in which the cross section orthogonal to the magnetic path is larger than the cross section orthogonal to the magnetic path of the C-shaped core piece (2). The end face of 3) is formed in a larger shape than the end face of the C-shaped core piece (2).

  As shown in FIG. 5, the bobbin (8) is composed of a boat member (87) formed by integrally molding resin and a mold resin wall (81) formed by insert molding as described later, and the whole is a square tube. It has a shape.

  As shown in FIG. 4 (a), the boat member (87) has a flat bottom wall (87a) and a pair of side walls (87b) (87b) vertically projecting from both ends of the bottom wall (87a). As shown in FIG. 4B, a plurality of metal plates (31) constituting a rectangular parallelepiped core piece (3) are assembled to the boat member (87). The plurality of metal plates (31) are held by the boat member (87) in a stacked state and are not easily separated. Therefore, it is easy to handle the rectangular parallelepiped core piece (3) during the insert molding described later.

  As shown in FIGS. 3 and 5, the mold resin wall (81) constituting the bobbin (8) is formed by an insert mold including a boat member (87) holding a rectangular parallelepiped core piece (3). The bottom wall (87a) and the pair of side walls (87b) (87b) of the member (87) form a part of three wall surfaces of the bobbin (8) orthogonal to each other.

  In addition, ribs (85) and (86) are provided on the inner peripheral surface of the mold resin wall (81) of the bobbin (8) so as to sandwich the rectangular parallelepiped core piece (3) from both sides. At both ends of the resin wall (81), flanges (82) project outwardly. Here, the thickness of the ribs 85 and 86 is the same as the gap length G to be formed between the C-shaped core piece 2 and the rectangular parallelepiped core piece 3 as shown in FIG. Is formed.

  As shown in FIG. 5, one brim (82) of the bobbin (8) has one end face among the four end faces forming a quadrangular outer shape for locking the coil winding as will be described later. The two locking grooves (83) and (84) are recessed.

  In the above-described bobbin (8), a pair of side spaces (80), (80) are formed on both sides of the central space surrounded by the boat member (87). Here, the central space and the side space (80) have the same shape in the cross section perpendicular to the magnetic path of the core (1), and the rectangular parallelepiped core piece (3) is surrounded in the central space. Is accommodated without forming a gap.

A coil (7) is wound around the outer peripheral surface of the bobbin (8) as shown in FIGS.
The ends of the pair of C-shaped core pieces (2) and (2) are inserted into the pair of side spaces (80) and (80) of the bobbin (8) as shown in FIG. Is configured. In the core (1), the ribs (85) and (86) are interposed between the end face of the C-shaped core piece (2) and the end face of the rectangular parallelepiped core piece (3), and the core (1). In the magnetic path, predetermined gaps G are provided at four locations.

In the core (1), since the end face of the rectangular parallelepiped core piece (3) is formed in a shape larger than the end face of the C-shaped core piece (2), as shown in FIG. 6, the bobbin (8) The cross-sectional shape of the side space (80) is such that the shape of the end face of the C-shaped core piece (2) is enlarged by a predetermined distance S in the vertical direction and by a predetermined distance T in the left-right direction. Will have the shape.
The cross-sectional shape of the side space (80) of the bobbin (8) is the same as the end face of the tip of the C-shaped core piece (2), either in the vertical direction or in the horizontal direction. It is also possible to form the piece (2) in a shape enlarged in the winding thickness direction.

  Therefore, even if there is some variation in the shape of the C-shaped core piece (2), the end face of the C-shaped core piece (2) and the end face of the rectangular parallelepiped core piece (3) are in contact with each other. The relative position of both core pieces (2) and (3) can be adjusted so that the end face of the C-shaped core piece (2) is within the contour shape of the end face of the rectangular parallelepiped core piece (3). Thus, the facing area between the end face of the C-shaped core piece (2) and the end face of the rectangular parallelepiped core piece (3) exactly matches the area of the end face of the C-shaped core piece (2).

As shown in FIG. 2, the two lateral spaces of each bobbin (8) are filled with an adhesive (9) so as to surround the end of the C-shaped core piece (2). The C-shaped core piece (2) is fixed to the bobbin (8) by 9).
The adhesive (9) is also filled in a gap formed between the end face of the rectangular parallelepiped core piece (3) and the end face of the C-shaped core piece (2), whereby the rectangular parallelepiped core piece ( 3) and the C-shaped core piece (2) are connected and fixed to each other.

  In the assembly process of the coil device, as shown in FIG. 3, a pair of bobbins (8) and (8) containing a rectangular parallelepiped core piece (3) are arranged in a serial positional relationship, and both bobbins (8) and (8) are arranged. Winding is applied to the outer peripheral surface. In the winding process, first, winding is sequentially performed on the bobbin in one direction while the winding start end portion (71) of the conducting wire is locked in one locking groove (83) of one bobbin (8). After the application, the wire is folded and wound sequentially in the opposite direction, and the conductor is locked in the other locking groove (84) of the bobbin.

  Subsequently, the crossover wire (72) that has passed through the locking groove (84) is locked to one locking groove (83) of the other bobbin (8), and in this state, the bobbin is unidirectional. After the sequential winding, it is folded back and sequentially wound in the reverse direction, and the conductor is locked to the other locking groove (84) of the bobbin, and the winding end end (73 ) Pull out.

  Next, one bobbin (8) is rotated 180 degrees with respect to the other bobbin (8), and both bobbins (8) and (8) are brought into a parallel positional relationship in which the buttocks contact each other as shown in FIG. Line up. Along with this, the connecting wire (72) extending from one coil (7) to the other coil (8) bends in an arc shape, and the adjacent locking grooves (84) of both bobbins (8), (8). (83) will be stretched at the shortest distance.

  After the winding process of the coils (7) and (7) on both bobbins (8) and (8), the tip ends of a pair of C-shaped core pieces (2) and (2) are inserted into both bobbins (8) and (8). Then, a pair of C-shaped core pieces (2) and (2) are fixed to both bobbins (8) and (8). Here, since the cross-sectional shape of the side space (80) of the bobbin (8) is larger than the cross-sectional shape of the tip portion of the C-shaped core piece (2), the insertion work is easy.

Prior to the insertion of the C-shaped core piece (2), the side space of the bobbin (8) is filled with an appropriate amount of adhesive, and the end of the C-shaped core piece (2) is bobbed by the adhesive. Fix to (8). The adhesive filled in the side space of the bobbin (8) flows backward from the back of the side space to the opening side with the insertion of the C-shaped core piece (2), and as shown in FIG. The end of the letter-shaped core piece (2) is covered with a large area. As a result, the C-shaped core piece (2) and the bobbin (8) are bonded in a large area, and a larger adhesive force can be obtained. .
Further, the adhesive (9) filled in the side space of the bobbin (8) is also filled in a region to be a magnetic gap between the C-shaped core piece (2) and the rectangular parallelepiped core piece (3). As a result, the C-shaped core piece (2) and the rectangular parallelepiped core piece (3) are connected and fixed to each other.

  In the coil device assembled in this way, the facing area between the end face of the C-shaped core piece (2) and the end face of the rectangular parallelepiped core piece (3) is the area of the end face of the C-shaped core piece (2). Therefore, the expected inductance characteristics can be obtained.

  In addition, the rectangular parallelepiped core piece (3) and the C-shaped core piece (2) can be produced using materials having different characteristics (for example, silicon steel plate, amorphous material, etc.), so that a combination of a plurality of materials is combined. It is possible to obtain characteristics.

In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, it is also possible to employ a configuration in which the end face of the C-shaped core piece (2) is formed larger than the end face of the rectangular parallelepiped core piece (3).
Further, the rectangular parallelepiped core piece (3) can be formed of a magnetic powder or a nanocrystalline material in addition to a silicon steel plate or an amorphous material.
Furthermore, the stacking direction of the rectangular parallelepiped core piece (3) may be the same direction or the direction intersecting with the stacking direction of the C-shaped core piece (2).

  Furthermore, the winding method and the locking method of the conducting wire with respect to the bobbin (8) are not limited to the above-described methods.

(1) Core
(2) C-shaped core piece
(3) Cuboid core piece
(31) Metal plate
(5) Coil assembly
(7) Coil
(8) Bobbin
(81) Mold resin wall
(87) Boat members
(80) Side space
(9) Adhesive

Claims (4)

  A coil is wound around an annular core, and the core includes a pair of C-shaped core pieces formed by dividing an annular wound core member produced by winding a metal strip, and the core A rectangular parallelepiped core piece interposed between a pair of C-shaped core pieces, and a magnetic gap portion interposed between facing surfaces of the C-shaped core piece and the rectangular parallelepiped core piece, and each other via the magnetic gap portion One of the opposing end faces of the C-shaped core piece and the end face of the rectangular parallelepiped core piece has a shape obtained by enlarging the shape of the other end face.   2. The coil device according to claim 1, wherein the one end face has a shape obtained by enlarging the shape of the other end face from the center thereof in four directions.   The coil device according to claim 1, wherein the end face of the rectangular parallelepiped core piece has a shape in which the shape of the end face of the C-shaped core piece is enlarged in the winding thickness direction of the C-shaped core piece.   A bobbin having a rectangular tube shape through which the core passes is provided, and the coil is wound around an outer peripheral surface of the bobbin. A central space in which the rectangular parallelepiped core piece is to be accommodated is formed in the bobbin. In addition, a lateral space into which the tip of the C-shaped core is to be inserted is formed on both sides of the central space, and the cross-sectional shape of the lateral space is that of the end surface of the C-shaped core piece. An outer peripheral surface of the tip portion of the C-shaped core piece and an inner peripheral surface of the bobbin in a state where the shape of the C-shaped core piece is inserted into the side space of the bobbin. The coil apparatus in any one of Claim 1 thru | or 3 with which synthetic resin is filled between.

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