JP2013187455A - Coil and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil capable of reducing the probability of vibrating adjacent annular parts to let them contact each other, and reducing the cost, and a method of manufacturing the coil.SOLUTION: In a coil material 1, a coupling part 1c couples one end of an annular part 1a having a partially missing part to one end of an annular part 1b having a circumference shorter than that of the annular part 1a, and the projection part 1d externally projects to the annular part 1b. A coil material is provided by folding and bending the annular parts 1a and 1b at the coupling part 1c, so as to let them overlap each other with an interval. In a coil material 2, a coupling part 2c couples one end of an annular part 2a having an almost identical configuration and shape to those of the annular part 1a, to one end of an annular part 2b having a circumference shorter than that of the annular part 2a, and the projection part 2d externally projects to the annular part 2b. The coil material is provided by folding and bending the annular parts 2a and 2b at the coupling part 2c, so as to let them overlap each other with an interval. The coil is provided by overlapping the projection parts 1d and 2d and connecting them.

Description

  The present invention relates to a coil configured by bending a coil material cut out from a metal plate by punching or cutting, and a method for manufacturing the coil.

  Currently, many smoothing circuits for smoothing a rectified direct current voltage are mounted on a vehicle. The smoothing circuit, for example, converts a battery output voltage into a voltage according to an in-vehicle device such as a light and a blower motor. It is mounted on the DC converter.

  The smoothing circuit is mainly composed of a coil and a capacitor. As a coil mounted on a vehicle, a coil configured by bending a coil material cut out from a metal plate by punching or cutting is widely used.

  Since the vehicle travels on an uneven road, the vehicle body vibrates while the vehicle travels. Therefore, the coil mounted on the vehicle vibrates together with the vehicle body, and adjacent annular portions among the plurality of annular portions constituting the coil come into contact with each other, which may reduce the coil inductance.

  Patent Document 1 discloses a coil that is configured by bending a coil material cut out from a metal plate and has a low probability of contact between adjacent annular portions due to vibration.

  The coil described in Patent Document 1 includes a cylindrical bobbin that is attached to the inside of the coil main body, and a protruding portion made of an insulator is provided on the outside of the bobbin. In the coil described in Patent Document 1, since the protrusions are provided between the adjacent annular portions, the probability that the adjacent annular portions due to vibration are in contact with each other is low.

Japanese Patent No. 4356828

  However, the coil described in Patent Document 1 is provided with a bobbin, and the shape of the coil body must be a special shape that can be fitted with a bobbin having a protrusion, and is therefore expensive. There is a problem.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide an inexpensive coil having a low probability of contact between adjacent annular portions due to vibration, and a method for manufacturing the coil. is there.

  The coil according to the present invention includes a first annular portion that is partially missing, a second annular portion that is shorter in circumference than the circumferential length of the first annular portion, and the first and second annular portions, respectively. The first and second annular portions are spaced apart from each other by a coil material including a first connecting portion connecting one end and a first protruding portion projecting outward from the second annular portion on the same plane. A first coil member formed by being bent at the first connecting portion so as to be spaced apart, a third annular portion having substantially the same shape and dimensions as the first annular portion, and a circumferential length of the third coil portion. A fourth annular portion that is shorter than the circumferential length of the annular portion, a second connecting portion that connects one end of each of the third and fourth annular portions, and a second protruding outwardly from the fourth annular portion. The coil material including the protruding portion on the same plane is overlapped with the third and fourth annular portions spaced apart from each other. As such, a second coil member which had been formed by bending at the second connecting portion, characterized in that is connected to overlap the first and second projecting portions.

  In the present invention, in the coil material, one end of the first annular portion that is partially missing and one end of the second annular portion that is shorter in circumference than the first annular portion are connected by the first connecting portion. The first projecting portion projects outwardly from the second annular portion. The first and second annular portions, the first connecting portion, and the first protruding portion are on the same plane. A first coil member is formed by bending the first connecting portion of the coil material such that the first and second annular portions overlap with each other with a gap therebetween.

  In the other coil material, the second end is one end of the third annular portion whose shape and dimensions are substantially the same as the first annular portion, and one end of the fourth annular portion whose peripheral length is shorter than the peripheral length of the third annular portion. The second projecting portion projects outwardly from the fourth annular portion. The third and fourth annular portions, the second connecting portion, and the second protruding portion are on the same plane. The second coil member is formed by bending the second connecting portion so that the third and fourth annular portions overlap each other with a gap therebetween. The first and second projecting portions are connected in an overlapping state.

  By the connection of the first and second projecting portions, the second and fourth annular portions form an annular portion having substantially the same shape and size in plan view as the first or third annular portion. The first and second protruding portions can be used not only for connecting the first and second coil members but also for fixing to peripheral members, for example, wall surfaces. Therefore, there is a low probability that the adjacent annular portions in the annular portion formed by the second and fourth annular portions and the first and third annular portions are in contact with each other due to vibration.

  Moreover, the bobbin for suppressing the contact between adjacent annular parts is unnecessary. Furthermore, since each of the first and second coil members is a member manufactured by bending the coil material only once, it can be easily manufactured. For this reason, the manufacturing cost is low.

  The coil according to the present invention is characterized in that the first and second projecting portions are overlapped so that a fourth annular portion is located between the first and second annular portions.

  In the present invention, since the first and second projecting portions are overlapped so that the fourth annular portion is located between the first and second annular portions, the first and second annular portions are formed by the second and fourth annular portions. The thickness in the direction in which the annular portion and the first and third annular portions are juxtaposed is short and compact.

  The method for manufacturing a coil according to the present invention includes a first annular portion that is partially missing, a second annular portion that has a circumference shorter than the circumference of the first annular portion, and the first and second annular portions. Cutting out a first coil material including a first connecting portion connecting one end of each portion and a first protruding portion protruding outward from the second annular portion from the metal plate; A step of bending the first coil material at the first connecting portion such that the first and second annular portions overlap with each other at a distance; and a third annular shape having substantially the same shape and dimensions as the first annular portion. A portion, a fourth annular portion having a circumferential length shorter than a circumferential length of the third annular portion, a second coupling portion coupling one end of each of the third and fourth annular portions, and the fourth annular portion A second coil member including a second protruding portion protruding outward in the same plane on a metal plate A step of cutting out, a step of bending at the second connecting portion so that the third and fourth annular portions overlap each other at an interval, and a step of overlappingly connecting the first and second projecting portions. It is characterized by.

In the present invention, in the first coil material cut out from the metal plate, one end of the first annular portion, which is partially missing, and the second annular shape, whose peripheral length is shorter than the peripheral length of the first annular portion. One end of the portion is connected by the first connecting portion, and the first protruding portion protrudes from the vicinity of the other end of the second annular portion. The first and second annular portions, the first connecting portion, and the first protruding portion are on the same plane.
The first coil material is bent so that the first and second annular portions overlap with each other at an interval.

In the second coil material cut out from the metal plate, one end of the third annular portion whose shape and dimensions are substantially the same as the first annular portion, and a fourth annular portion whose peripheral length is shorter than the peripheral length of the third annular portion Are connected to each other by the second connecting portion, and the second protruding portion protrudes outward from the fourth annular portion. The third and fourth annular portions, the second connecting portion, and the second protruding portion are on the same plane.
The second coil material is bent so that the third and fourth annular portions overlap with each other at an interval.

  A coil is manufactured by overlappingly connecting the first protruding portion of the bent first coil material and the second protruding portion of the bent second coil material. In this way, by cutting out the first and second coil materials from the metal plate and bending and connecting the cut out first and second coil materials, an inexpensive coil having a low probability of contact between adjacent annular portions due to vibration is obtained. Manufactured.

  According to the present invention, it is possible to realize an inexpensive coil having a low probability of contact between adjacent annular portions due to vibration, and a method for manufacturing the coil.

It is a top view of the coil material which concerns on this invention. It is a perspective view of the coil member comprised by bending of a coil material. It is a perspective view of the coil manufactured by connection of two coil members. It is explanatory drawing for demonstrating that a coil is compact.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments thereof.
FIG. 1 is a plan view of a coil material according to the present invention. There are two coil materials according to the present invention. FIG. 1A shows a plan view of one coil material 1 and FIG. 1B shows a plan view of the other coil material 2. Each of the coil materials 1 and 2 is cut out from a metal plate by punching or cutting. Each of the coil materials 1 and 2 may be cut out from the same metal plate, or may be cut out separately from two metal plates.

  The coil material 1 has a rectangular annular portion 1a that is partially missing, and the circumferential length is shorter than the circumferential length of the annular portion 1a and the other shapes and dimensions except the circumferential length are substantially the same as the annular portion 1a. The annular part 1b which shortened the perimeter of the annular part 1a, and the connection part 1c which has connected the end of each of the annular parts 1a and 1b are provided. The coil material 1 further includes a protruding portion 1d protruding in the direction away from the connecting portion 1c in the vicinity of the other end of the annular portion 1b.

  The coil material 1 includes annular portions 1a and 1b, a connecting portion 1c, and a protruding portion 1d on the same plane. The projecting portion 1 d is provided with a through hole 1 e that penetrates in a direction perpendicular to the plate surface of the coil material 1.

The other end of the annular portion 1a is formed with a connecting portion 1f for connecting to an electric wire. The connecting portion 1f is provided with a through hole 1g penetrating in a direction perpendicular to the plate surface of the coil material 1. It has been.
In addition, a straight line L1 passing through the approximate center between the lower side of the annular portion 1a and the upper side of the annular portion 1b is virtually shown in the connecting portion 1c.

  The coil material 1, the annular portion 1a, the annular portion 1b, the connecting portion 1c and the protruding portion 1d are respectively the first coil material, the first annular portion, the second annular portion, the first connecting portion and the first protruding portion in the claims. Corresponds to the part.

  The coil material 2 has an annular portion 2a whose shape and dimensions are substantially the same as the annular portion 1a, and a circumferential length shorter than the circumferential length of the annular portion 2a and excluding the circumferential length, and other shapes and dimensions are substantially the same as the annular portion 2a. The same, ie, the annular part 2b which shortened the perimeter of the annular part 2a, and the connection part 2c which has connected one end of each of the annular parts 2a and 2b are provided. The coil material 2 further includes a protruding portion 2d protruding in the direction away from the connecting portion 2c in the vicinity of the other end of the annular portion 2b.

  The coil material 2 includes annular portions 2a and 2b, a connecting portion 2c, and a protruding portion 2d on the same plane. The protruding portion 2d is provided with a through hole 2e penetrating in a direction perpendicular to the plate surface of the coil material 2.

The other end of the annular portion 2a is formed with a connecting portion 2f for connecting to an electric wire. The connecting portion 2f is provided with a through hole 2g penetrating in a direction perpendicular to the plate surface of the coil material 2. It has been. The shapes and dimensions of the through holes 1g and 2g are substantially the same.
In the connecting portion 2c, a straight line L2 that passes through the approximate center between the left side of the annular portion 2a and the right side of the annular portion 2b is virtually shown.

  The coil material 2, the annular portion 2a, the annular portion 2b, the connecting portion 2c, and the protruding portion 2d are respectively the second coil material, the third annular portion, the fourth annular portion, the second connecting portion, and the second protruding portion in the claims. Corresponds to the part.

  The sum of the circumference of the annular portion 1b and the circumference of the annular portion 2b exceeds the circumference of the annular portion 1a (or the annular portion 2a). Each of the annular portions 1b and 2b is configured by shortening the circumferential length of the annular portions 1a and 2a, and the shape and dimensions of the annular portion 2a are substantially the same as those of the annular portion 1a. Therefore, by overlapping the annular portions 1b and 2b, an annular portion having substantially the same shape and size in plan view as the annular portion 2a (or the annular portion 2a) can be formed.

  The projecting portion 1d (or projecting portion 2d) is an annular portion 2b (or annular portion 1b) when the annular portions 1b and 2b are overlapped to form an annular portion having substantially the same shape and dimensions in plan view as the annular portion 1a. Is provided outward at the position of the annular portion 1b (or the annular portion 2b) that overlaps with. The projecting portion 1d (or projecting portion 2d) is the same as the projecting portion 2d (or projecting portion 1d) when the annular portions 1b and 2b are overlapped to form an annular portion having substantially the same shape and size in plan view as the annular portion 1a. It is provided in the annular part 1b (or the annular part 2b) so as to overlap.

  When the projecting portions 1d and 2d are overlapped to form an annular portion having substantially the same shape and dimensions in plan view as the annular portion 1a (or the annular portion 2a), the annular portion formed by the annular portion 1a and the annular portions 1b and 2b The portion and the annular portion 2a are arranged in an L shape on the same plane, and the straight lines L1 and L2 are orthogonal to each other.

  FIG. 2 is a perspective view of a coil member formed by bending the coil members 1 and 2. FIG. 2A shows a coil member 3 configured by bending the connecting portion 1c into a convex shape along the straight line L1 so that the straight line L1 is on the outside. Similarly, FIG. 2B shows the coil member 4 configured by bending the coupling portion 2c into a convex shape along the straight line L2 so that the straight line L2 is inside.

The coil member 3 is configured by bending the connecting portion 1c of the coil material 1 so that the annular portions 1a and 1b overlap with a gap, and the coil member 4 has the annular portions 2a and 2b overlapping with a gap. In addition, the connecting portion 2c of the coil material 2 is bent.
The coil members 3 and 4 correspond to the first and second coil members in the claims.

  The coil member 3 is provided with a bent portion 3a formed by bending the connecting portion 1c along the straight line L1, and the coil member 4 has a bent portion formed by bending the connecting portion 2c along the straight line L2. A portion 4a is provided.

  FIG. 3 is a perspective view of a coil manufactured by connecting two coil members 3 and 4. The coil 5 is manufactured by overlapping and connecting the protruding portions 1d and 2d such that the annular portion 2b is positioned between the annular portions 1a and 1b.

  Here, the annular portions 1b and 2b constitute an annular portion having substantially the same shape and dimensions in plan view as the annular portion 1a (or the annular portion 2a). The annular portion 1a, the annular portion formed by the annular portions 1b and 2b, and the annular portion 2a are coaxially overlapped with an interval. Furthermore, the through holes 1e and 2e are configured to coincide with each other when the annular portions 1b and 2b form an annular portion having substantially the same shape and dimensions as the annular portion 1a (or the annular portion 2a) in plan view. ing. Using the through holes 1e and 2e, the protruding portions 1d and 2d are connected in an overlapping state.

  The coil 5 has a pair of electric wires connected to the connecting portions 1f and 2f using the through holes 1g and 2g, respectively. Thereby, the coil 5 is connected to another element or apparatus via a pair of electric wires.

  The connecting portions 1f and 2f and the protruding portions 1d and 2d are also used for fixing the coil 5 to a member around the coil 5, for example, a wall surface. Even if the coil 5 is mounted on a vehicle and vibrates with the vehicle, the adjacent annular portions of the annular portions 1a and 2a and the annular portion formed by the annular portions 1b and 2b come into contact with each other. The probability of doing is low. Thereby, the fall of the inductance of the coil 5 by the contact of an adjacent annular part is prevented.

  Further, as described in the description of the coil materials 1 and 2, when the protruding portions 1d and 2d are overlapped, the straight lines L1 and L2 are orthogonal to each other, so that the bent lines of the bent portions 3a and 4a in the coil 5 are orthogonal to each other. Accordingly, since the annular portions 1a and 2a and the annular portion formed by the annular portions 1b and 2b are supported from a plurality of directions, the probability that the adjacent annular portions are in contact with each other when the coil 5 vibrates is even lower. .

  Further, since the coil members 3 and 4 can be easily manufactured by bending the coil materials 1 and 2 only once, the manufacturing cost of the coil 5 is low.

  FIG. 4 is an explanatory diagram for explaining that the coil 5 is compact. FIG. 4A is a conceptual side view of the coil 5. FIG. 4B is a side view of a conventional coil 6 formed by bending a single coil member cut from a metal plate twice. In FIG. 4A, in order to easily understand that the coil 5 is compact, the bent portions 3a and 4a are shown on both the left and right sides, and the bent portions 3a and 4a are not shown in the correct positions.

  When the coil material 1, 2 or the coil material used for forming the conventional coil 6 is bent, the distance between the two parts facing each other is substantially the same, and is indicated by Wr in FIGS. 4A and 4B. Yes. The thicknesses of the coil materials 1 and 2 and the coil material used for forming the conventional coil 6 are also substantially the same, and are indicated by Wt in FIGS. 4A and 4B.

  In the coil 5 in which the coil members 3 and 4 are overlapped so that the annular portion 2b is positioned between the annular portions 1a and 1b, as shown in FIG. 4A, the thickness in the vertical direction is (2Wr + 2Wt). Here, the “vertical direction” is a direction in which the annular portion 1a, the annular portion formed by the annular portions 1b and 2b, and the annular portion 2a are juxtaposed.

On the other hand, the thickness of the conventional coil 6 in the vertical direction is (2Wr + 3Wt) as shown in FIG. 4B.
Therefore, the thickness of the coil 5 according to the present invention is shorter than the thickness of the conventional coil 6 by Wt, and the coil 5 is compact.

  There is a lower limit to the interval Wr formed by bending the coil materials 1 and 2 or the coil material used for forming the conventional coil 6. When the coils 5 and 6 are disposed in a place where the space is limited, for example, in a vehicle, the interval Wr between the coils 5 and 6 is designed to be a lower limit or a value close to the lower limit.

  Therefore, the coil 5 is shorter than the coil 6 by Wt in the vertical direction and is compact, and is therefore suitable as a coil disposed in a place where the space is limited, for example, in a vehicle.

  In the present embodiment, the coil materials 1 and 2 are cut out from the metal plate by punching or cutting. The coil member 3 is formed by bending the coil material 1 into a convex shape along a straight line L1 of the connecting portion 1c so that the annular portions 1a and 1b overlap with each other with a gap therebetween. Similarly, the coil member 4 is formed by bending the coil material 2 into a convex shape along the straight line L2 of the connecting portion 2c so that the annular portions 2a and 2b overlap with each other with a gap therebetween. The coil 5 is manufactured by overlapping and connecting the protruding portions 1d and 2d so that the annular portion 2a is positioned between the annular portions 1a and 1b.

  The coil member 1 is formed by bending the connecting portion 1c into a convex shape along the straight line L1 so that the straight line L1 is inside, and the coil member 2 is straight line L2 so that the straight line L2 is outside. A coil may be formed from a coil member formed by bending the connecting portion 2c along the projection. The coil has the same effect as the coil 5.

  The place where the protruding portions 1d and 2d are provided is not limited to the vicinity of the other end of the annular portions 1b and 2b. The projecting portion 1d (or projecting portion 2d) is an annular portion 2b (or annular portion 1b) when the annular portions 1b and 2b are overlapped to form an annular portion having substantially the same shape and dimensions in plan view as the annular portion 1a. It is only necessary to be provided outward at the position of the annular portion 1b (or the annular portion 2b) that overlaps.

  At this time, the protruding portion 1d (or protruding portion 2d) is formed when the annular portions 1b and 2b are overlapped to form an annular portion having substantially the same shape and size in plan view as the annular portion 1a. 1d) is provided on the annular portion 1b (or the annular portion 2b) so as to overlap.

Moreover, the shape of each of the annular portions 1a and 2a is not limited to a rectangle, and may be, for example, a circle.
Further, the protruding portions 1d and 2d may not be overlapped so that the annular portion 2b is positioned between the annular portions 1a and 1b. For example, the interval between the annular portions 1a and 1b is the interval between the annular portions 1a and 2b. The annular portion 2b may be overlapped so as to be shorter than the annular portion 1b in FIG. 3 or 4A.

  Since the coil to which the coil members 3 and 4 are connected in this manner can use the connection portions 1f and 2f and the protruding portions 1d and 2d for fixing the coil in the same manner as the coil 5, the annular portion 1a, There is a low probability that an annular portion formed by the annular portions 1b and 2b and an annular portion adjacent to each other in the annular portion 2a come into contact by vibration. Moreover, since the coil members 3 and 4 can be easily manufactured by bending the coil materials 1 and 2 only once, the manufacturing cost is low.

  The disclosed embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

1, 2 Coil material 1a, 1b, 2a, 2b Annular part 1c, 2c Connection part 1d, 2d Protruding part 3, 4 Coil member 5 Coil

Claims (3)

A first annular part that is partially missing, a second annular part that has a circumference shorter than the circumference of the first annular part, and a first part that connects one end of each of the first and second annular parts. A coil member including a connecting portion and a first projecting portion projecting outward from the second annular portion on the same plane, such that the first and second annular portions overlap with each other at an interval; A first coil member configured to be bent at a first connecting portion;
A third annular portion having substantially the same shape and dimensions as the first annular portion, a fourth annular portion having a circumferential length shorter than the circumferential length of the third annular portion, and the third and fourth annular portions, respectively. The third and fourth annular portions are spaced apart from each other by a coil material including a second connecting portion connecting one end and a second protruding portion protruding outward from the fourth annular portion on the same plane. A second coil member configured to be bent at the second connecting portion so as to overlap with each other, and
The coil characterized in that the first and second projecting portions are overlapped and connected. The coil according to claim 1, wherein the first and second projecting portions are overlapped so that a fourth annular portion is positioned between the first and second annular portions. A first annular part that is partially missing, a second annular part that has a circumference shorter than the circumference of the first annular part, and a first part that connects one end of each of the first and second annular parts. Cutting a first coil material from a metal plate that includes one connecting portion and a first protruding portion protruding outward from the second annular portion on the same plane;
Bending the first coil material at the first connecting portion so that the first and second annular portions overlap with each other at an interval;
A third annular portion having substantially the same shape and dimensions as the first annular portion, a fourth annular portion having a circumferential length shorter than the circumferential length of the third annular portion, and the third and fourth annular portions, respectively. Cutting a second coil material from a metal plate, which includes a second connecting portion connecting one end and a second protruding portion protruding outward from the fourth annular portion on the same plane;
Bending the second connecting portion so that the third and fourth annular portions overlap with each other at an interval;
And a step of overlapping and connecting the first and second projecting portions.

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