JP2013089656A - Wiring element coil and wiring element - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wiring element coil which achieves insulation between adjacent layers when a belt like conductive member is wound, decreases thickness of a portion between the layers, and to provide the wiring element using the same.SOLUTION: A wiring element coil 1A includes an insulating member 12 having a long beltlike conductive member 11, a one surface covering section 12a for covering one whole side surface of the conductive member 11, a pair of first and second end face covering sections 12b-1 and 12b-2 for respectively covering both ends in a width direction of the conductive member 11, and a pair of first and second other surface covering sections 12c-1 and 12c-2 which are respectively extended from the pair of first and second end face covering sections 12b-1 and 12b-2 and cover a part of the other side surface of the conductive member 11. The conductive member 11 covered by the insulating member 12 is wound so that its width direction is aligned in an axial direction of the coil 1A.

Description

  The present invention relates to a coil for a winding element used for a winding element in which a long conductor member is wound, and a winding element using the coil for a winding element.

  A winding element wound with a long conductor member has a reactor (coil) intended to introduce reactance into the circuit, and energy between multiple windings (coils) by using electromagnetic induction. Transformers (transformers, transformers) that perform transmission are known. This reactor is used, for example, in various electric circuits and electronic circuits such as prevention of harmonic currents in power factor correction circuits, smoothing of current pulsations in current type inverter and chopper control, and boosting of DC voltage in converters. Yes. Transformers are used in various electric circuits, electronic circuits, and the like in order to perform voltage conversion, impedance matching, current detection, and the like.

  As a coil for a winding element used for such a winding element such as a reactor or a transformer, for example, a wire rod having a circular cross section (◯ shape), a rectangular cross section (□ shape), or a long strip member is used. ing. The coil for a winding element using the long strip-shaped member is configured by winding the strip-shaped conductor member so that the width direction of the conductor member is along the radial direction of the coil. An edgewise coil and a flatwise coil (pancake coil) configured by winding a strip-shaped conductor member so that the width direction of the conductor member is along the axial direction of the coil are known. ing. In this flatwise coil, when a pair of core members through which magnetic flux passes are arranged at both ends in the width direction of the strip-shaped conductor member, the direction of the magnetic flux generated when the coil is energized is along the width direction. Compared with the edgewise type coil, the eddy current loss can be reduced.

  Such flatwise coils are disclosed in, for example, Patent Document 1 and Patent Document 2. FIG. 11 is a diagram showing the structure of a conventional flatwise coil. FIG. 11A is a perspective view showing the structure of the pancake coil disclosed in Patent Document 1, and FIG. 11B is a perspective view showing the structure of the pancake coil disclosed in Patent Document 2. is there. FIG. 12 is a diagram showing a band-shaped conductor member with insulation coating used in a conventional flatwise coil.

  As shown in FIG. 11A, a coil 1000 disclosed in Patent Document 1 is a pancake coil 1000 configured by winding conductors 1001 in multiple layers, and an interlayer insulation 1002 between each layer conductor 1001 The coil is bonded to the conductors 1001A and 1001B on both sides of the interlayer insulation 1002 and has a difference between the adhesive strength on one side of the interlayer insulation 1002 and the adhesive strength on the other side. Note that both ends of the conductor 1001 are an inner lead portion 1003 and an outer lead portion 1004 in order to electrically connect the coil 1000 to the outside.

  In addition, as shown in FIG. 11B, the coil 1100 disclosed in Patent Document 2 is configured such that a plurality of conductors 1101 are metallurgically connected by metallurgical connection portions 1103 and the conductor 1101 is subjected to interlayer insulation 1102. A coil is formed by winding a predetermined number of pancakes and applying ground insulation 1104 to the whole. Note that both ends of the conductor 1101 are an inner terminal 1105 and an outer terminal 1106 in order to electrically connect the coil 1100 to the outside.

  Incidentally, in the coils 1000 and 1100 disclosed in Patent Document 1 and Patent Document 2, interlayer insulations 1002 and 1102 having the same width as that of the conductors 1001 and 1101 are formed only on both side surfaces of the strip-shaped conductors 1001 and 1101. Therefore, when the coils 1000 and 1100 are tightened, so-called burrs at the ends of the conductors 1001 and 1101 bite into the interlayer insulation 1002 and 1102, or the interlayer insulation 1002 and 1102 shift in the width direction. In each layer adjacent to each other, a leakage current may occur at the end portions in the width direction of the strip-like conductors 1001 and 1101. Further, in the coil 1000 disclosed in Patent Document 1, the conductor 1001 and the interlayer insulation 1002 are bonded to each other. However, since their expansion rates are different, they may eventually be peeled off over time.

  Therefore, as shown in FIG. 12, an insulating tape member such as polyethylene naphthalate (PEN) is spirally wound (wrapped) on the strip-shaped conductor member 1201 so that a part thereof overlaps each other. A coil is known that is formed by covering the entire conductor member 1201 with an insulating tape member and then winding the conductor member 1201 into a pancake shape.

JP 55-076598 A Japanese Patent Laid-Open No. 56-078103 (Japanese Patent Publication No. 60-008611)

  However, in the case where a flatwise type coil is configured with a conductive member in which the insulating tape member is spirally wound, the insulating tape member overlaps with a part of one side surface of the conductive member, and is laminated in two layers. Between the layers adjacent to each other in the wound conductor member, the insulating tape member is laminated in four layers at this lamination point. For this reason, the coil having such a configuration has a four-fold increase in the interlayer thickness compared to the case where the interlayer is insulated by a single-layer insulating tape member. For this reason, the coil of such a structure becomes large in diameter in the radial direction and becomes large in diameter. Since the inductance decreases when the diameter is increased, it is necessary to increase the number of turns in order to obtain a desired inductance, which further increases the diameter of the coil. In the coil for a winding element, since a plurality of conductor members are wound, it is not preferable that there are a plurality of layers and the thickness of the layers is increased. Further, the problem of increasing the diameter of the coil becomes serious especially when the winding element is arranged in a limited space (space) such as a circuit board.

  The present invention has been made in view of the above circumstances, and its object is to achieve insulation at the end portions between adjacent layers when a strip-shaped conductor member is wound, while the thickness between the layers is increased. It is providing the coil for winding elements which can reduce a thickness, and the winding element using this coil for winding elements.

  As a result of various studies, the present inventor has found that the above object is achieved by the present invention described below. That is, a coil for a winding element according to one aspect of the present invention includes a long strip-shaped conductor member, a one surface covering portion that covers the entire one side surface of the conductor member, and a width direction of the one surface covering portion. A pair of first and second end cover portions extending from both ends and covering both ends of the conductor member in the width direction, and extending from each of the pair of first and second end cover portions; An insulating member including a pair of first and second other surface covering portions covering a part of the other side surface of the member facing the one side surface, and the one surface covering portion of the insulating member and the pair of first surfaces. The conductor member covered with the first and second end cover portions and the pair of first and second other surface cover portions is wound so that the width direction is along the axial direction of the coil. And Preferably, in the coil for a winding element, the insulating member is a long strip-shaped member having a width longer than that of the conductor member, and the conductor member is overlapped with the insulating member. And both ends in the width direction are covered with both sides in the width direction of the insulating member by folding back both sides in the width direction of the insulating member, and the width direction is wound so as to follow the axial direction of the coil. ing.

  In the coil for a winding element having such a configuration, both ends in the width direction of the conductor member are covered with the pair of first and second end covering portions, so that when the strip-shaped conductor member is wound, Insulation at the edges between adjacent layers is achieved. When the strip-shaped conductor member is wound, the thickness between the adjacent layers becomes the thickness of two insulating members of the one surface covering portion and the other surface covering portion. It is reduced to half compared to.

  In another aspect, the coil for a winding element described above further includes a second insulating member that wraps the wound conductor member.

  In the coil for a winding element having such a configuration, since the wound conductor member is wrapped by the second insulating member, insulation from the outside is more reliably realized.

  According to another aspect, the coil for a winding element described above further includes a pair of upper insulating members and lower insulating members that cover both ends in the width direction of the wound conductor member. .

  In the coil for a winding element having such a configuration, both ends in the width direction of the wound conductor member are covered with the upper insulating member and the lower insulating member, respectively, so that insulation between the both ends from the outside is further improved. Realized reliably.

  A winding element according to another aspect includes any one of the above-described winding element coils and a core portion through which a magnetic flux generated by the winding element coil passes.

  In the winding element having such a configuration, since both sides in the width direction of the conductor member are covered with both sides in the width direction of the folded insulating member, when the belt-like conductor member is wound, Insulation at the edges between adjacent layers is achieved. And since only the both sides in the width direction of the insulating member are folded back, when the strip-shaped conductor member is wound, the thickness between adjacent layers becomes the thickness of two insulating members, The thickness is reduced by half compared to the conventional thickness.

  According to another aspect, in the winding element described above, the core portion includes a pair of an upper core member and a lower core member that cover both ends in the axial direction of the coil for the winding element.

  In the winding element having such a configuration, the insulation between the one end in the width direction of the wound conductor member and the upper core member, and the other end in the width direction of the wound conductor member Insulation with the lower core member is more reliably realized.

  The coil for a winding element and the winding element according to the present invention can reduce the thickness between the layers while realizing insulation at an end portion between adjacent layers when a strip-shaped conductor member is wound. it can.

It is a figure which shows the structure of the reactor using the coil for winding elements in any one of 1st thru | or 3rd embodiments. It is a perspective view which shows the structure of the core member in the reactor shown in FIG. In the reactor shown in FIG. 1, it is a figure which shows the structure of the coil for winding elements of 1st Embodiment. It is a figure which shows the conductor member and 1st insulating member which are used for the coil for winding elements of 1st Embodiment. In the reactor shown in FIG. 1, it is a figure which shows the structure of the coil for winding elements of 2nd Embodiment. In the reactor shown in FIG. 1, it is a figure which shows the structure of the coil for winding elements of 3rd Embodiment. It is a figure which shows the manufacturing method for manufacturing the reactor using the coil for winding elements in 1st Embodiment. It is a figure which shows each item and each result in an Example and a comparative example. It is a figure which shows the measurement system for measuring Q value. It is a figure which shows the measurement system for performing a dielectric strength test. It is a figure which shows the structure of the conventional flatwise type | mold coil. It is a figure which shows the strip | belt-shaped conductor member which carried out the insulation coating used for the conventional flatwise type | mold coil.

  Hereinafter, an embodiment according to the present invention will be described with reference to the drawings. In addition, the structure which attached | subjected the same code | symbol in each figure shows that it is the same structure, The description is abbreviate | omitted suitably. Further, in this specification, when referring generically, it is indicated by a reference symbol without a suffix, and when referring to an individual configuration, it is indicated by a reference symbol with a suffix.

  The coil for a winding element according to the present embodiment includes a long strip-shaped conductor member and a long strip-shaped insulating member having a width longer than the width of the conductor member, and the conductor member includes the insulating member. The both ends in the width direction of the insulating member are covered with the both sides in the width direction of the insulating member, and the width direction is in the axial direction of the coil. It is wound so as to follow. Such a coil for a winding element is used in a reactor for the purpose of introducing reactance into a circuit, or a transformer that transmits energy between a plurality of windings (coils) by using electromagnetic induction. Used for (transformers, transformers). For example, in a reactor, a coil for a winding element composed of one coil formed by winding the conductor member overlapped with the insulating member as described above is used. Further, for example, in a multi-phase reactor, a coil for a winding element including a plurality of coils formed by winding a plurality of conductor members stacked on the insulating member as described above is used. In addition, for example, in a transformer, a coil for a winding element including a plurality of coils formed by winding a plurality of the conductor members stacked on the insulating member as described above is used.

  Here, a coil for a winding element for a reactor and a reactor using the same are illustrated, but a coil for a winding element for a multiphase reactor or a transformer and an apparatus (device) using the same are also configured. It is possible.

(Reactor of the embodiment)
The reactor in this embodiment is demonstrated. FIG. 1 is a diagram illustrating a configuration of a reactor using a coil for a winding element according to any one of the first to third embodiments. The cross section in FIG. 1 is a plane cut by a plane including the axis O. FIG. 2 is a perspective view showing a configuration of a core member in the reactor shown in FIG.

  In the reactor D (DA, DB, DC) in this embodiment, any one of the winding element coils 1A, 1B, 1C in the first to third embodiments described later is used. . That is, FIG. 1 shows a reactor DA including the winding element coil 1A of the first embodiment, a reactor DB including the winding element coil 1B of the second embodiment, and a winding element coil 1C of the third embodiment. The reactor DC provided is shown collectively.

  In FIG. 1, a reactor D (DA, DB, DC) includes a winding element coil 1 (1A, 1B, 1C) having a flatwise winding structure, and a core portion 2 covering the winding element coil 1. It has.

  The coil 1 for a winding element is extended from both ends in the width direction of the long side strip-shaped conductor member, one surface covering portion covering the entire one side surface of the conductor member, and the one surface covering portion. Extending from each of the pair of first and second end cover portions covering both ends in the width direction, and the pair of first and second end cover portions, facing the one side surface of the conductor member. An insulating member including a pair of first and second other surface covering portions covering a part of the other side surface, the one surface covering portion of the insulating member and the pair of first and second end portion covering portions. And the conductor member covered with the pair of first and second other surface covering portions is a flatwise coil (pancake coil) wound so that the width direction is along the axial direction of the coil. is there. Then, first and second lead wires (outlet wires) 5 for electrically connecting an external circuit and the coil for winding element 1 (the conductor member) to both ends of the conductor member, respectively. -1, 5-2 are connected. Details of the coil 1 for a winding element will be described later.

  The core portion 2 is a member that allows a magnetic flux generated by the magnetic field generated in the winding element coil 1 to pass through when the winding element coil 1 is energized, and is magnetically (for example, magnetic permeability) isotropic. . For example, as shown in FIGS. 1 and 2, the core portion 2 includes first and second lead wiring through holes 3e-1 and 3e-2 through which the first and second lead wirings 5-1 and 5-2 are passed. Are provided with first and second core members 3 and 4 having the same configuration except that they are provided on one core member. The first and second core members 3 and 4 are, for example, cylindrical portions 3b having outer peripheral surfaces having the same diameter as the disc portions 3a and 4a on the disc surfaces 3a and 4a having disc shapes, for example. 4b is continuously formed. In the example shown in FIG. 1, the first and second lead wiring through holes 3e-1 and 3e-2 are formed in the disc portion 3a of the first core member 3 so as to penetrate the disc portion 3a in the axial direction. Is formed. The core portion 2 accommodates the coil 1 for winding element in the first and second core members 3 and 4 having such a configuration by overlapping each other at the end surfaces of the cylindrical portions 3b and 4b. It has a space for.

  In the example shown in FIG. 1 and FIG. 2, when the winding element coil 1 is accommodated in the core part 2, the core part 2 faces the air core part S of the winding element coil 1. A protrusion that enters the air core S is formed. More specifically, when the coil for winding element 1 is accommodated in the core portion 2, the void is formed at a location facing the air core portion S of the coil for winding element 1 on the inner bottom surface of the first core member 3. A first frustoconical projection 3 f that enters the core S is formed, and the winding element coil on the inner bottom surface of the second core member 4 when the winding element coil 1 is accommodated in the core part 2. A frustoconical second protrusion 4 f that enters the air core S is formed at a location facing the one air core S. By forming such first and second protrusions 3f and 4f, the inductance of the reactor D can be further improved. Moreover, the inductance value of the reactor D can be adjusted by adjusting the gap length between each projection part 3f, 4f. Further, the first and second protrusions 3f and 4f can have any shape in order to control the inductance characteristics, and are not limited to the truncated cone shape. Also good.

  The first and second core members 3 and 4 are provided with convex portions 3c and 4c for positioning on the respective end surfaces of the cylindrical portions 3b and 4b that are overlapped with each other, and according to the convex portions 3c and 4c. Recesses 3d and 4d are provided. Such convex portions 3c and 4c and concave portions 3d and 4d may be omitted. For example, as shown in FIG. 2, substantially cylindrical first and second convex portions 3 c-1 and 3 c-2 are provided on the end surfaces of the cylindrical portions 3 b and 4 b in the first and second core members 3 and 4; 4c-1, 4c-2 are provided at an interval of 180 ° (positions facing each other), and such substantially cylindrical first and second convex portions 3c-1, 3c-2; 4c-1, 4c- The first and second concave portions 3d-1, 3d-2; 4d-1, 4d-2 having substantially cylindrical shapes in which 2 is fitted are provided at intervals of 180 ° (positions facing each other). And these 1st and 2nd convex parts 3c-1, 3c-2; 4c-1, 4c-2 and 1st and 2nd recessed parts 3d-1, 3d-2; 4d-1, 4d-2 are respectively , Provided at intervals of 90 °. In the example shown in FIG. 2, the first and second core members 3 and 4 have the same shape. In FIG. 2, the first and second core members 3 and 4 including the protrusions 3 f and 4 f are shown. One of the is shown. The first and second core members 3 and 4 can be more reliably abutted by further providing the positioning convex portions 3c and 4c on the end surfaces of the cylindrical portions 3b and 4b.

  The first and second core members 3 and 4 have predetermined magnetic characteristics. The first and second core members 3 and 4 are preferably made of the same material from the viewpoint of cost reduction. Here, the first and second core members 3 and 4 are formed by molding a soft magnetic powder from the viewpoint of easy realization of desired magnetic properties (relatively high magnetic permeability) and ease of forming a desired shape. It is preferable that

  This soft magnetic powder is a ferromagnetic metal powder. More specifically, for example, pure iron powder, iron-based alloy powder (Fe-Al alloy, Fe-Si alloy, Sendust, Permalloy, etc.) and amorphous powder, Furthermore, the iron powder etc. with which electric insulation films, such as a phosphoric acid system chemical film, were formed on the surface are mentioned. These soft magnetic powders can be produced by, for example, the atomizing method. In general, since the saturation magnetic flux density is large when the magnetic permeability is the same, the soft magnetic powder is preferably a metal material such as the above pure iron powder, iron-based alloy powder, and amorphous powder. Such first and second core members 3 and 4 can be formed, for example, by compacting soft magnetic powder using known conventional means.

  Such a reactor D in this embodiment is, for example, for industrial inverters such as electric railway vehicles, electric vehicles, hybrid vehicles, uninterruptible power supplies, solar power generation, or high-output home appliances such as air conditioners, refrigerators, washing machines, etc. It can be suitably used for an inverter.

  In the above-described reactor D, the winding element coil 1 and the core portion 2 have a cylindrical outer shape as a basic shape. However, the present invention is not limited to this, and a polygonal column shape may be used as a basic shape. Good. Examples of the polygonal column shape include a quadrangular column shape, a hexagonal column shape, and an octagonal column shape. Moreover, it is good also considering each shape of cylindrical shape and polygonal-prism shape as a basic shape. For example, the winding element coil 1 may have a cylindrical shape, and the core portion 2 may have a polygonal column shape. For example, the winding element coil 1 may have a polygonal column shape, and the core portion 2 may be a cylindrical shape.

  In the above-described embodiment, from the viewpoint of improving insulation and heat dissipation, between the upper end surface of the coil for winding element 1 and the inner wall surface of the first core member 3 of the core portion 2 opposed thereto, An insulating material such as BN (boron nitride) ceramic may be filled between the lower end surface of the wire element coil 1 and the second core member 4 of the core portion 2 facing the lower end surface. As the insulating material, for example, an insulating and good heat conductive resin sheet is assumed, and the thickness is preferably 1 mm or less. The insulating material may be filled with a compound.

  By this insulating material, the insulation between the upper end surface of the coil for winding element 1 and the inner wall surface of the first core member 3 of the core portion 2 facing it, or the lower end surface of the coil for winding element 1 faces it. Insulation between the core part 2 and the second core member 4 is improved. The insulating material improves the thermal conductivity in the axial direction (vertical direction) by the coil for winding element 1, and Joule heat generated in the coil for winding element 1 passes through the insulating material to the core portion 2. As a result, the reactor D having such a configuration can efficiently waste heat to the outside. For this reason, by cooling the core part 2 more specifically from the outside, it is possible to prevent the inside of the reactor D from becoming hot.

  Next, the winding element coils 1A, 1B, and 1C of the first to third embodiments used in the reactor D will be described in order.

(Coil for winding element of the first embodiment)
FIG. 3 is a diagram showing a configuration of the coil for winding element of the first embodiment in the reactor shown in FIG. 3A is a top view of the coil for the winding element, FIG. 3B is a side view of the coil for the winding element, and FIG. 3C is FIG. 3B. It is a partial cross section enlarged view in the location shown with the broken-line circle. FIG. 4 is a diagram illustrating a conductor member and a first insulating member used in the coil for winding element according to the first embodiment.

  The coil for winding element 1A according to the first embodiment is provided with a cylindrical air core portion S having a predetermined diameter at the center (axial core) O, and is formed in a long strip shape having a predetermined first thickness ( A coil formed by winding a predetermined number of pieces of tape-like or ribbon-like conductor member 11 into a pancake shape while sandwiching a long strip-like insulating member 12 having a predetermined second thickness. Both ends in the width direction (axial direction) 11 are also covered with the insulating member 12. The first and second lead wires 5-1 and 5-2 are connected to both ends of the conductor member 11 in the longitudinal direction so as to be electrically conductive. Here, the band shape means that the member has a rectangular cross section in which the ratio t / W of the thickness t of the member to the width W of the member is smaller than 1. When a flatwise coil is formed, the width W of the member is the length in the axial direction, and the thickness t of the member is the length in the radial direction.

  More specifically, as shown in FIG. 3, the insulating member 12 is extended from both ends in the width direction of the one surface covering portion 12 a and the one surface covering portion 12 a covering the entire one side surface of the conductor member 11, A pair of first and second end cover portions 12b-1 and 12b-2 covering both ends in the width direction of the conductor member 11, and a pair of first and second end cover portions 12b-1 and 12b-2 A pair of first and second other surface covering portions 12 c-1 and 12 c-2 extending from the respective members and covering a part of the other side surface of the conductor member 11 facing the one side surface are provided. In the example shown in FIG. 3, a part of the other side surface of the conductor member 11 is covered by the pair of first and second other surface covering portions 12 c-1 and 12 c-2. The entire other side surface of the conductor member 11 may be covered by bringing the ends of the second other surface covering portions 12c-1 and 12c-2 into contact with each other without overlapping.

  One surface covering portion 12a of the insulating member 12, a pair of first and second end covering portions 12b-1, 12b-2, and a pair of first and second other surface covering portions 12c-1, 12c-2. For example, the conductor member 11 covered with is produced as follows. In FIG. 4, first, the conductor member 11 is overlapped with a long strip-shaped insulating member 12 having a width longer than the width of the conductor member 11, thereby forming the one surface covering portion 12 a. Subsequently, by folding back both side portions 12d-1 and 12d-2 in the width direction of the insulating member 12, both ends in the width direction of the insulating member 12 and both side portions in the width direction of the other surface are both side portions of the insulating member in the width direction. Thus, a pair of first and second end cover portions 12b-1 and 12b-2 and a pair of first and second other surface cover portions 12c-1 and 12c-2 are formed. In the example shown in FIG. 4, the one side covering portion 12 a, the pair of first and second end covering portions 12 b-1, 12 b-2, and the pair of the long strip-shaped insulating members 12 are thus formed. First and second other surface covering portions 12c-1 and 12c-2 are formed. For example, a metal (including an alloy) such as copper is used for the conductor member 11, and a resin having heat resistance such as PEN (polyethylene naphthalate) or PPS (polyphenylene sulfide) is used for the insulating member 12. Used.

  And the coil 1A for winding elements of 1st Embodiment is accommodated in the space formed by each inner surface of the 1st and 2nd core members 3 and 4, for example, and reactor DA is comprised by this.

If the thickness of the conductor member 11 is larger than the so-called skin thickness δ, the eddy current loss generated inside the conductor member 11 increases. From the viewpoint of reducing the eddy current, the thickness t of the conductor member 11 is The skin thickness is preferably δ or less. The same applies to the following embodiments. This skin thickness δ is given by the following equation when the angular frequency is ω, the magnetic permeability is μ, and the electrical conductivity is σ.
δ = (2 / ωμσ) ^1/2

  In such a winding element coil 1A of the first embodiment and the reactor DA using the same, both ends of the conductor member 11 in the width direction are paired with the first and second end covering portions 12b-1, 12b-. 2, when the strip-shaped conductor member 11 is wound, insulation at the end portions between adjacent layers is realized. When the strip-shaped conductor member 11 is wound, the thickness between adjacent layers becomes the thickness of two insulating members of the one surface covering portion 12a and the other surface covering portion 12c. Is reduced by half compared to the prior art.

  In the reactor DA using the winding element coil 1A of the first embodiment, both ends in the width direction of the conductor member 11 are paired with the first and second end covering portions 12b-1, 12b-. 2, insulation between one end in the width direction of the coil for winding element 1 </ b> A and the disc portion 3 a of the first core member 3 (disc portion 4 a of the second core member 4), and Insulation between the other end of the winding element coil 1A in the width direction and the disc portion 4a of the second core member 4 (the disc portion 3a of the first core member 3) is more reliably realized.

  The disc portion 3a of the first core member 3 (disc portion 4a of the second core member 4) corresponds to an example of the upper core member, and the disc portion 4a of the second core member 4 (first core member). 3 disk portion 3a) corresponds to an example of a lower core member. In the example shown in FIG. 1, the core portion 2 further includes cylindrical portions 3 b and 4 b, and the reactor D shown in FIG. 1 is a so-called pot in which the winding element coil 1 </ b> A is accommodated in the core portion 2. A type reactor. In other words, the pot-type reactor D includes a pair of upper core member and lower core member covering both ends in the axial direction of the coil 1 for the winding element, and the pair of upper core member and lower core member as their outer peripheral edge portions. The coil 1 for a winding element is accommodated in a core portion including cylindrical outer core members that are connected to each other. The above-described configuration is suitable for such a pot-type reactor D.

(Coil for winding element of the second embodiment)
FIG. 5 is a diagram showing a configuration of a coil for winding element of the second embodiment in the reactor shown in FIG. 5A is a top view of a coil for a winding element, FIG. 5B is a side view of the coil for a winding element, and FIG. 5C is a view of FIG. 5B. It is a partial cross section enlarged view in the location shown with the broken-line circle.

  The winding element coil 1 </ b> B according to the second embodiment further includes a second insulating member 13 that wraps the conductor member 11 wound with the insulating member 12. More specifically, the coil for winding element 1B includes, for example, as shown in FIG. 5, one surface covering portion 12a of the insulating member 12 and a pair of first and second end covering portions 12b-1, 12b. -2 and the pair of first and second other surface covering portions 12c-1 and 12c-2 are formed by winding the conductor member 11 so that the width direction thereof is along the axial direction of the coil 1B. An annular body (ring-shaped body, donut-shaped body) is formed by, for example, further wrapping with a sheet-like second insulating member 13. In other words, the coil for winding element 1B is formed by further wrapping the coil for winding element 1A of the first embodiment with, for example, a sheet-like second insulating member 13. By wrapping the annular body (the coil for winding element 1A of the first embodiment), the sheet-like second insulating member 13 becomes tubular (tubular). As the first insulating member 12, for example, a resin having heat resistance such as PEN or PPS is used for the second insulating member 13.

  And the coil 1B for winding elements of 2nd Embodiment is accommodated in the space formed by each inner surface of the 1st and 2nd core members 3 and 4, for example, and reactor DB is comprised by this.

  Such a winding element coil 1B and the reactor DB using the same in the second embodiment, in addition to the effects of the winding element coil 1A of the first embodiment and the reactor DA using the same, By further including the second insulating member 13, the insulation between the coil for winding element 1 </ b> B and the core portion 2 can be more reliably realized, and the withstand voltage can be further improved.

(Coil for winding element of the third embodiment)
FIG. 6 is a diagram showing a configuration of a coil for winding element of the third embodiment in the reactor shown in FIG. 6A is a side view of the coil for a winding element, and FIG. 6B is an enlarged partial cross-sectional view at a portion indicated by a broken-line circle in FIG. 5A.

  The winding element coil 1 </ b> C according to the third embodiment further includes a third insulating member 14 that covers both ends in the width direction of the conductor member 11 wound with the insulating member 12. More specifically, for example, as shown in FIG. 6, the third insulating member 14 includes a first surface covering portion 12 a of the insulating member 12 and a pair of first and second end covering portions 12 b-1 and 12 b-2. And the conductor member 11 covered with the pair of first and second other surface covering portions 12c-1 and 12c-2 is wound so that the width direction thereof is along the axial direction of the coil 1C for winding element. An upper insulating member 14-1 that is an annular plate that covers the end face of one end in the axial direction of the annular body, and a lower insulating member that is an annular plate that covers the end face of the other end in the axial direction of the annular body 14-2. In other words, in the coil for winding element 1C, one end face (upper end face) in the axial direction of the coil for winding element 1A of the first embodiment is covered with the upper insulating member 14-1 of the annular plate. In both cases, the end surface (lower end surface) at the other end in the axial direction of the coil for winding element 1A of the first embodiment is covered with the lower insulating member 14-2 of the annular plate. For the third insulating member 14, as in the case of the first and second insulating members 12 and 13, for example, a heat-resistant resin such as PEN or PPS is used.

  In the example shown in FIG. 6, the upper insulating member 14-1 includes a short-height inner peripheral cylindrical portion and an outer peripheral cylindrical portion that extend from the inner peripheral edge and the outer peripheral edge of the annular plate body. The lower insulating member 14-2 includes a short-high inner peripheral cylindrical portion and an outer peripheral cylindrical portion that extend from the inner peripheral edge and the outer peripheral edge of the annular plate body.

  And the coil 1C for winding elements of 3rd Embodiment is accommodated in the space formed by each inner surface of the 1st and 2nd core members 3 and 4, for example, and reactor DC is comprised by this.

  The winding element coil 1C and the reactor DC using the same according to the third embodiment include the third embodiment in addition to the effects of the winding element coil 1A according to the first embodiment and the reactor DA. By further including the insulating member 14, the insulation between the coil for winding element 1 </ b> C and the core portion 2 at both ends can be more reliably realized, and the dielectric strength can be further improved.

  In the above description, the winding element coil 1C in the third embodiment is the innermost circumference of the conductor member 11 wound with the insulating member 12 in order to more reliably insulate and improve the dielectric strength. A fourth insulating member (not shown) that covers the inner peripheral side surface may be further provided, and a fifth insulating member that covers the outermost outer peripheral side surface of the conductor member 11 wound with the insulating member 12. (Not shown) may be further provided.

(Reactor manufacturing method)
Next, a method for manufacturing the reactors DA, DB, and DC using the first to third winding element coils 1A, 1B, and 1C will be described. Here, a manufacturing method for manufacturing the reactor DA using the winding element coil 1A in the first embodiment will be described, but instead of the winding element coil 1A in the first embodiment, a second winding element is used. Similarly, by using the coil 1B for the reactor, the reactor DB can be manufactured, and the coil 1C for the winding element in place of the coil 1A for the winding element in the first embodiment can be used similarly. In addition, the reactor DC can be manufactured.

  FIG. 7 is a diagram illustrating a manufacturing method for manufacturing a reactor using the coil for the winding element in the first embodiment.

  In FIG. 7, first, as shown in FIG. 7A, a long strip-shaped conductor member 11 is placed on a long strip-shaped insulating member 12 having a longer (wider) width than the width of the conductor member 11. Overlaid. Subsequently, as shown in FIG. 7B, both side portions 12 d-1 and 12 d-2 in the width direction of the insulating member 12 are folded to return both ends in the width direction and both side portions in the width direction of the other surface of the insulating member 12. Is covered on both sides of the insulating member 12 in the width direction.

  Subsequently, as shown in FIG. 7C, the conductor member 11 with the insulating member 12 is wound a predetermined number of times from a position spaced from the center (axial core) O by a predetermined diameter. Thereby, the coil 1A for winding elements of the pancake structure provided with the columnar air core part S which has a predetermined diameter in the center is formed.

  Subsequently, as shown in FIG. 7D, the first and second core members 3 and 4 are overlapped on the end surfaces of the cylindrical portions 3b and 4b so as to sandwich the coil for winding element 1A. Thereby, for example, a disk-shaped reactor DA as shown in FIG.

Next, examples and comparative examples will be described.
(Examples and Comparative Examples)
FIG. 8 is a diagram showing specifications and results in Examples and Comparative Examples. FIG. 9 is a diagram showing a measurement system for measuring the Q value. FIG. 10 is a diagram showing a measurement system for conducting a dielectric strength test.

  As shown in FIG. 8, the coils for the winding elements in Examples 1 to 6, Comparative Example 1 and Comparative Example 2 have the same conductor member and the same number of turns, and the presence or absence of the insulating member and the second insulating member. Is different. The commonly used conductor member is pure copper having a width of 20 mm and a thickness of 0.3 mm, and the common number of turns is 30 turns.

  The coil for winding elements of Examples 1 to 3 (Sample No. 3 to Sample No. 5) is a specific configuration of the coil for winding element 1A of the first embodiment. In Example 1 (Sample No. 3), the insulating member 12 is a resin tape (PEN tape) having a width of 26 mm and a thickness of 0.025 mm, and the folded first and second other surface covering portions 12c-1 and 12c. Each of -2 is 3 mm long. In Example 2 (Sample No. 4), the insulating member 12 is a resin tape (PEN tape) having a width of 30 mm and a thickness of 0.025 mm, and the folded first and second other surface covering portions 12c-1 and 12c. Each of -2 is 5 mm long. In Example 3 (sample No. 5), the insulating member 12 is a resin tape (PEN tape) having a width of 34 mm and a thickness of 0.025 mm, and the folded first and second other surface covering portions 12c-1 and 12c. Each of -2 is 7 mm long.

  Moreover, the reactor of Example 4 thru | or Example 6 (sample No. 6 thru | or sample No. 8) concretely comprises the coil 1B for winding elements of 2nd Embodiment. The second insulating member 13 is common to the fourth to sixth embodiments and is an insulating film having a thickness of 0.05 mm. In Example 4 (Sample No. 6), the insulating member 12 is a resin tape (PEN tape) having a width of 26 mm and a thickness of 0.025 mm, and the folded first and second other surface covering portions 12c-1 and 12c. Each of -2 is 3 mm long. In Example 5 (Sample No. 7), the insulating member 12 is a resin tape (PEN tape) having a width of 30 mm and a thickness of 0.025 mm, and the folded first and second other surface covering portions 12c-1 and 12c. Each of -2 is 5 mm long. In Example 6 (Sample No. 8), the insulating member 12 is a resin tape (PEN tape) having a width of 34 mm and a thickness of 0.025 mm, and the folded first and second other surface covering portions 12c-1 and 12c. Each of -2 is 7 mm long.

  On the other hand, the coils for the winding elements of Comparative Example 1 and Comparative Example 2 (Sample No. 1 and Sample No. 2) are the first and second end cover portions 12b-1, 12b-2 and There is no insulating member corresponding to the first and second other surface covering portions 12c-1 and 12c-2, and a coil in which a conductor member and an insulating member are simply overlapped and wound is used. The coil of Comparative Example 1 (Sample No. 1) corresponds to, for example, the pancake coil disclosed in Patent Document 2. And the comparative example 2 (sample No. 2) encloses such an entire coil with an insulating film. In Comparative Example 1 (Sample No. 1), the insulating member is a resin tape (PEN tape) having a width of 20 mm and a thickness of 0.025 mm. In Comparative Example 2 (Sample No. 2), the insulating member is a resin tape (PEN tape) having a width of 20 mm and a thickness of 0.025 mm, and the insulating film wrapping the entire coil is 0.05 mm in thickness.

  For each of the reactors of Examples 1 to 6, Comparative Example 1 and Comparative Example 2, the Q value was measured and the withstand voltage test was performed. The Q value is an index reflecting the AC loss (eddy current loss), and the AC loss (eddy current loss) is smaller when the Q value is higher (larger). For this reason, a larger Q value is desirable because of higher efficiency.

  In the measurement of the Q value, as shown in FIG. 9, the coil Ob to be measured is sandwiched between a pair of upper and lower disk-shaped core members, and the LCR meter 23 is connected to the lead wire of the coil Ob to be measured. . In such a measurement system, AC power having a frequency of 10 kHz to 20 kHz with a voltage of 1 V was supplied to the coil Ob to be measured, and the Q value was measured by the LCR meter 23.

  In the dielectric strength test, as shown in FIG. 10, for example, a coil Ob to be measured is placed on a conductor plate 31 made of aluminum, and an AC power supply 32 is connected to one lead wiring in the coil Ob to be measured. It was done. In such a measurement system, AC power with a commercial frequency of 50 Hz was fed to the coil Ob to be measured, and the dielectric strength was tested by boosting from 0 V to 2.0 kV in one minute. The dielectric breakdown voltage is evaluated as acceptable when the leakage current is less than 0.5 mA for 1 minute with 2.0 kV applied after boosting. On the other hand, the leakage current of 0.5 mA or more after boosting starts. Is determined to be unacceptable. The applied voltage when the leakage current of 0.5 mA or more flows is the withstand voltage.

  Such a Q value measurement result and a dielectric strength test were performed a plurality of times for one coil Ob to be measured, and the Q value was an average value thereof. These results are as shown in FIG.

  In the withstand voltage test, Examples 1 to 6 and Comparative Example 2 had a withstand voltage of 2.0 kV or more and passed the withstand voltage test, but Comparative Example 1 had a withstand voltage of 0.96. It was about ˜1.11 kV and failed the dielectric strength test.

  In the measurement of the Q value, when the measurement value (average Q value) of Example 1 is 100, the Q value of Example 2 is 107, and the Q value of Example 3 is 105. The Q value of Example 4 was 98, the Q value of Example 5 was 101, and the Q value of Example 6 was 103. On the other hand, the Q value of Comparative Example 1 was 13 (average value of measurement result ranges 2 to 35), and the Q value of Comparative Example 2 was 17 (average value of measurement result ranges 3 to 45). . As a result, in the first comparative example and the second comparative example, when AC power is supplied, leakage current flows between the layers of the coil Ob to be measured (this is referred to as a fine short circuit) and is generated in the coil Ob. The inventors of the present invention speculate that an increase in eddy current loss is presumed and, for this reason, the Q value is low. On the other hand, in Examples 1 to 6, it was presumed that there was no such fine short circuit, and the Q value was good.

  In order to express the present invention, the present invention has been properly and fully described through the embodiments with reference to the drawings. However, those skilled in the art can easily change and / or improve the above-described embodiments. It should be recognized that this is possible. Therefore, unless the modifications or improvements implemented by those skilled in the art are at a level that departs from the scope of the claims recited in the claims, the modifications or improvements are not covered by the claims. To be construed as inclusive.

DA, DB, DC reactor 1A, 1B, 1C Winding element coil 11 Conductor member 12 Insulating member 13 Second insulating member 14 Third insulating member 14-1 Upper insulating member 14-2 Lower insulating member

Claims (6)

A long strip-shaped conductor member;
A first surface covering portion covering the entire one side surface of the conductor member, and a pair of first and second ends extending from both ends in the width direction of the one surface covering portion and covering both ends in the width direction of the conductor member, respectively. A pair of first and second other surfaces extending from each of the portion covering portion and the pair of first and second end covering portions and covering a part of the other side surface of the conductor member facing the one side surface An insulating member provided with a covering portion,
The conductor member covered by the one surface covering portion of the insulating member, the pair of first and second end portion covering portions, and the pair of first and second other surface covering portions has a width direction of a coil. A coil for a winding element, which is wound along an axial direction. The insulating member is a long band-shaped member having a width longer than the width of the conductor member,
The conductor member is overlapped with the insulating member, and both ends in the width direction are covered with both side portions in the width direction of the insulating member by folding back both sides in the width direction of the insulating member. The winding element coil according to claim 1, wherein the coil is wound so as to be along an axial direction of the coil. The coil for winding elements according to claim 1, further comprising a second insulating member that wraps the conductor member that is wound. The coil for winding elements according to claim 1 or 2, further comprising a pair of an upper insulating member and a lower insulating member that cover both ends in the width direction of the wound conductor member. A coil for a winding element according to any one of claims 1 to 4,
A winding element comprising: a core portion through which a magnetic flux generated by the coil for the winding element passes. The winding element according to claim 5, wherein the core portion includes a pair of an upper core member and a lower core member that cover both ends in the axial direction of the coil for the winding element.

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