JP2017073486A - Coil component - Google Patents

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JP2017073486A
JP2017073486A JP2015200052A JP2015200052A JP2017073486A JP 2017073486 A JP2017073486 A JP 2017073486A JP 2015200052 A JP2015200052 A JP 2015200052A JP 2015200052 A JP2015200052 A JP 2015200052A JP 2017073486 A JP2017073486 A JP 2017073486A
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core
metal
metal core
sectional area
winding
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尚史 川村
Hisashi Kawamura
尚史 川村
清人 小野
Kiyoto Ono
清人 小野
勝 篠田
Masaru Shinoda
勝 篠田
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FDK Corp
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FDK Corp
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Abstract

PROBLEM TO BE SOLVED: To provide a coil component capable of effectively suppressing copper loss of a winding with a simple structure and facilitating accommodation of a high current.SOLUTION: The coil component includes a winding 4 at an outer periphery of a magnetic core 1. The magnetic core 1 is formed into a square shape with a ferrite core 2 and a metal core 3, a winding 4 is provided at least around an outer periphery of the metal core 3, and a cross section of the metal core 3 is set to be smaller than that of the ferrite core 2.SELECTED DRAWING: Figure 1

Description

本発明は、磁性コアに巻線を施したトランスやチョークコイル等のコイル部品に関するものである。   The present invention relates to a coil component such as a transformer or a choke coil in which a magnetic core is wound.

従来から、図６に示すような口字状の磁性コア１０の脚部の外周に巻線１１を施したコイル部品や、図７に示すように日字状の磁性コア１２の中足部１２ａの外周に巻線１３を施したコイル部品においては、上記磁性コア１０、１２として、通常フェライトコアが用いられている。   Conventionally, a coil component in which a winding 11 is provided on the outer periphery of a leg portion of a mouth-shaped magnetic core 10 as shown in FIG. 6, or a middle leg portion 12a of a day-shaped magnetic core 12 as shown in FIG. In a coil component having a winding 13 on the outer periphery, a ferrite core is usually used as the magnetic cores 10 and 12.

ところで、近年、例えばハイブリッド車のＤＣ−ＤＣコンバータ等のような１ｋＷ以上の大電力の電源に用いられるトランスやチョークコイル等のコイル部品においては、上記巻線１１、１３を流れる電流が大きいことから、当該巻線１１、１３の電気抵抗に起因した銅損が大きくなるという問題点が生じている。   By the way, in recent years, in a coil component such as a transformer or a choke coil used for a high-power power source of 1 kW or more such as a DC-DC converter of a hybrid vehicle, the current flowing through the windings 11 and 13 is large. There is a problem that the copper loss due to the electrical resistance of the windings 11 and 13 becomes large.

そこで、このような問題点を解決するために、コア１０やコア１２の中足部１２ａを従来よりも細くして、同じターン数に対する巻線１１、１３の全長を短くすることにより、当該巻線１１、１３の電気抵抗を低減する対策が考えられる。しかしながら、コア１０や中足部１２ａを細くすると磁束密度が高まるために、飽和磁束密度が低いフェライトコアでは上記大電流化への対応には限度がある。   Therefore, in order to solve such a problem, the core 10 and the core 12 of the core 12 are made thinner than before, and the total length of the windings 11 and 13 with respect to the same number of turns is shortened. A measure for reducing the electrical resistance of the wires 11 and 13 can be considered. However, since the magnetic flux density increases when the core 10 or the middle foot portion 12a is thinned, there is a limit to dealing with the large current in the ferrite core having a low saturation magnetic flux density.

なお、下記特許文献１においては、電子レンジ等の高周波誘電加熱に用いられる昇圧トランスにおいて、一次側に流れるピーク電流をさらに増加させる際に、飽和磁束密度が低いフェライトコアを飽和し難くするために、金属コアを一次巻線と二次巻線とヒータ巻線の外側から棒状のフェライトコアに向けて嵌挿したものが開示されている。   In Patent Document 1 below, in a step-up transformer used for high-frequency dielectric heating such as a microwave oven, when further increasing the peak current flowing on the primary side, it is difficult to saturate a ferrite core having a low saturation magnetic flux density. A metal core is inserted into a rod-shaped ferrite core from the outside of a primary winding, a secondary winding, and a heater winding.

特開２００３−２７２９３２号公報JP 2003-272932 A

本発明は、上記事情に鑑みてなされたものであり、簡易な構造により巻線の銅損を効果的に低減し、大電流化に容易に対応することが可能になるコイル部品を提供することを課題とするものである。   The present invention has been made in view of the above circumstances, and provides a coil component that can effectively reduce copper loss of a winding with a simple structure and can easily cope with a large current. Is an issue.

上記課題を解決するため、請求項１に記載の発明は、磁性コアの外周に巻線を施したコイル部品において、上記磁性コアをフェライトコアおよび金属コアによって口字状に構成し、少なくとも上記金属コアの外周に上記巻線を施すとともに、上記金属コアの断面積を、上記フェライトコアの断面積よりも小さくしたことを特徴とするものである。   In order to solve the above-mentioned problem, the invention according to claim 1 is a coil component in which a winding is provided on the outer periphery of a magnetic core, wherein the magnetic core is formed in a letter shape by a ferrite core and a metal core, and at least the metal The winding is applied to the outer periphery of the core, and the cross-sectional area of the metal core is made smaller than the cross-sectional area of the ferrite core.

また、請求項２に記載の発明は、磁性コアの外周に巻線を施したコイル部品において、上記磁性コアを、対向配置された一対の背部と、当該背部の両端部間に配置された一対の外足部と、上記背部の中央部間に配置された中足部とを有する日字状に形成し、上記背部および上記外足部をフェライトコアによって構成するとともに上記中足部を金属コアによって構成し、少なくとも上記金属コアの外周に上記巻線を施すとともに、上記金属コアの断面積を、その両側の上記外足部の合計断面積よりも小さくしたことを特徴とするものである。   According to a second aspect of the present invention, in the coil component in which the outer periphery of the magnetic core is wound, the magnetic core is disposed between a pair of back portions disposed opposite to each other and a pair of both ends of the back portion. The outer foot portion and the middle foot portion disposed between the center portions of the back portion are formed in a letter shape, and the back portion and the outer foot portion are formed of a ferrite core, and the middle foot portion is formed of a metal core. The winding is applied to at least the outer periphery of the metal core, and the cross-sectional area of the metal core is made smaller than the total cross-sectional area of the outer leg portions on both sides thereof.

請求項３に記載の発明は、請求項１または２に記載の発明において、上記金属コアが、ナノ結晶合金、アモルファス、パーマロイまたはセンダストからなることを特徴とするものである。   The invention according to claim 3 is the invention according to claim 1 or 2, characterized in that the metal core is made of a nanocrystalline alloy, amorphous, permalloy or sendust.

また、請求項４に記載の発明は、請求項１または２に記載の発明において、上記金属コアが、ナノ結晶合金、アモルファス、パーマロイまたはセンダストの金属磁性粉末をバインダーと混合して加圧成形した圧粉磁心（ダストコア）からなることを特徴とするものである。   According to a fourth aspect of the present invention, in the first or second aspect of the present invention, the metal core is pressure-molded by mixing a nanocrystalline alloy, amorphous, permalloy or sendust metal magnetic powder with a binder. It consists of a powder magnetic core (dust core).

請求項１〜４のいずれかに記載の発明によれば、磁性コアをフェライトコアと、これよりも飽和磁束密度が高い金属コアとによって構成するとともに、金属コアの断面積をフェライトコアの断面積よりも小さくし、かつ上記金属コアに巻線を施しているために、従来のようにフェライトコアの外周に巻線する場合と比較して、同じターン数に対する巻線の全長を短くして電気抵抗を低減することにより銅損を低減することができる。   According to the invention described in any one of claims 1 to 4, the magnetic core is composed of a ferrite core and a metal core having a saturation magnetic flux density higher than that, and the cross-sectional area of the metal core is set to the cross-sectional area of the ferrite core. Compared with the case of winding around the outer periphery of the ferrite core as in the conventional case, the total length of the winding for the same number of turns is shortened. Copper loss can be reduced by reducing the resistance.

しかも、巻線する金属コアの断面積を小さくしているために、巻線のためのスペースを増大させることができ、よって巻線自体の断面積（線径）を大きくして一層の電気抵抗の低減効果を得ることも可能になる。この結果、簡易な構造により巻線の銅損を効果的に低減して大電流化に対応することができる。   In addition, since the cross-sectional area of the metal core to be wound is reduced, the space for the winding can be increased, so that the cross-sectional area (wire diameter) of the winding itself is increased to further increase the electric resistance. It is also possible to obtain a reduction effect. As a result, it is possible to effectively reduce the copper loss of the windings with a simple structure and cope with an increase in current.

なお、請求項１または２に記載の発明において、上記金属コアの素材としては、純鉄、ケイ素鋼、ナノ結晶合金、アモルファス、パーマロイ、センダスト等の金属を用いることが可能であるが、特に請求項３、４に記載の発明のように、ナノ結晶合金、アモルファス、パーマロイ若しくはセンダスト、またはこれらの金属磁性粉末をバインダーと混合して加圧成形した圧粉磁心（ダストコア）を用いれば、より高い飽和磁束密度とともに、磁心損失も低く抑えることができるために好適である。   In the invention described in claim 1 or 2, as the material of the metal core, a metal such as pure iron, silicon steel, nanocrystalline alloy, amorphous, permalloy, sendust, etc. can be used. If the powder magnetic core (dust core) which pressure-molded nanocrystal alloy, amorphous, permalloy or sendust, or these metal magnetic powders with a binder like invention of claim | item 3 and 4 is used, it will be higher. Along with the saturation magnetic flux density, it is preferable because the core loss can be kept low.

本発明の第１の実施形態を示す斜視図である。1 is a perspective view showing a first embodiment of the present invention. 第１の実施形態の変形例を示す斜視図である。It is a perspective view which shows the modification of 1st Embodiment. 本発明の第２の実施形態を示す斜視図である。It is a perspective view which shows the 2nd Embodiment of this invention. 第２の実施形態の変形例を示す斜視図である。It is a perspective view which shows the modification of 2nd Embodiment. 本発明の第３の実施形態を示す斜視図である。It is a perspective view which shows the 3rd Embodiment of this invention. 従来のコイル部品を示す斜視図である。It is a perspective view which shows the conventional coil components. 従来の他のコイル部品を示す斜視図である。It is a perspective view which shows the other conventional coil components.

（第１の実施形態）
図１は、本発明のコイル部品の第１の実施形態を示すもので、図中符号１がこのコイル部品の磁性コアである。
この磁性コア１は、コ字状をなす板状のフェライトコア２と、このフェライトコア２の先端部間に配設された平板状の金属コア３とによって全体として口字状をなす筒状に形成されたもので、これらフェライトコア２と金属コア３とは、互いに接着または図示されないクリップやテープによって一体化されている。 (First embodiment)
FIG. 1 shows a first embodiment of a coil component according to the present invention. Reference numeral 1 in the drawing denotes a magnetic core of the coil component.
The magnetic core 1 is formed into a cylindrical shape having a square shape as a whole by a U-shaped plate-shaped ferrite core 2 and a flat metal core 3 disposed between the tip portions of the ferrite core 2. The formed ferrite core 2 and the metal core 3 are bonded to each other or integrated by a clip or a tape (not shown).

ここで、金属コア３は、ナノ結晶合金、アモルファス、パーマロイ、センダストまたはダストコアによって形成されたもので、その断面積がフェライトコア２の断面積よりも小さい板状に形成されている。そして、この金属コア３の外周に、巻線４が施されている。   Here, the metal core 3 is formed of a nanocrystalline alloy, amorphous, permalloy, sendust, or dust core, and has a cross-sectional area that is smaller than the cross-sectional area of the ferrite core 2. A winding 4 is provided on the outer periphery of the metal core 3.

なお、本実施形態においては、図２の変形例に示すように、コ字状をなすフェライトコア２の先端部の対向面間に、板状の金属コア３を配置するようにしてもよい。   In the present embodiment, as shown in the modification of FIG. 2, the plate-shaped metal core 3 may be disposed between the opposing surfaces of the tip portion of the U-shaped ferrite core 2.

（第２の実施形態）
図３は、本発明のコイル部品を示すもので、このコイル部品においては、磁性コア５が、平板状の背部５ａと、この背部５ａの両端に直角に形成された平板状の外足部５ｂと、背部５ａの中央部間に配置された円柱状の中足部６とによって全体として日字状に形成されている。 (Second Embodiment)
FIG. 3 shows a coil component according to the present invention. In this coil component, the magnetic core 5 has a flat plate-like back portion 5a and flat plate-like outer foot portions 5b formed at right angles on both ends of the back portion 5a. And a columnar middle leg portion 6 disposed between the central portions of the back portion 5a.

そして、背部５ａと外足部５ｂとが、フェライトコアによって一体に形成されるとともに、中足部６が金属コアによって形成されている。
この中足部６も、ナノ結晶合金、アモルファス、パーマロイ、センダストまたはダストコアによって形成されたもので、その断面積が背部５ａの断面積の２倍よりも小さく、かつ両側に位置する外足部５ｂの合計断面積よりも小さい円柱状に形成されている。そして、この中足部６に巻線４が施されている。 The back portion 5a and the outer foot portion 5b are integrally formed of a ferrite core, and the middle foot portion 6 is formed of a metal core.
The middle foot portion 6 is also formed of a nanocrystalline alloy, amorphous, permalloy, sendust or dust core, and its cross-sectional area is smaller than twice the cross-sectional area of the back portion 5a, and the outer foot portions 5b located on both sides. It is formed in a columnar shape smaller than the total cross-sectional area. The middle leg portion 6 is provided with a winding 4.

なお、本実施形態においては、図４に示すように、円柱状の金属コアからなる中足部６に変えて、背部５ａの中央部間に介装されるとともに断面積が背部５ａの断面積の２倍よりも小さく、かつ両側に位置する外足部５ｂの合計断面積よりも小さい平板状の金属コアからなる中足部７を用いることもできる。   In the present embodiment, as shown in FIG. 4, instead of the middle foot portion 6 made of a cylindrical metal core, the cross-sectional area is interposed between the central portions of the back portion 5 a and the cross-sectional area is the cross-sectional area of the back portion 5 a. It is also possible to use the middle foot portion 7 made of a flat metal core that is smaller than 2 times and smaller than the total cross-sectional area of the outer foot portions 5b located on both sides.

（第３の実施形態）
図５は、本発明の第３の実施形態を示すもので、このコイル部品は、第１の実施形態に示した磁性コイル１の金属コア３の外周に、一次側（または二次側）巻線４を施すとともに、フェライトコア２の上記金属コア３と対向する位置の外周に二次側（または一次側）巻線８を施したものである。 (Third embodiment)
FIG. 5 shows a third embodiment of the present invention, and this coil component is wound around the outer periphery of the metal core 3 of the magnetic coil 1 shown in the first embodiment on the primary side (or secondary side). A wire 4 is applied, and a secondary side (or primary side) winding 8 is provided on the outer periphery of the ferrite core 2 at a position facing the metal core 3.

以上の構成からなる第１〜第３の実施形態に示したコイル部品においては、磁性コア１、５をフェライトコア２、５ａ、５ｂと、これよりも飽和磁束密度が高い金属コア３、６、７によって構成するとともに、金属コア３の断面積をフェライトコア２の断面積より小さくし、また金属コア６、７の断面積をフェライトコア５ａの断面積の２倍より小さく、かつフェライトコア５ｂの断面積の２倍よりも小さくして、これら金属コア３、６、７に巻線を施しているために、従来のようにフェライトコアの外周に巻線する場合と比較して、同じターン数に対する巻線４の全長を短くして電気抵抗を低減することにより銅損を低減することができる。   In the coil components shown in the first to third embodiments configured as described above, the magnetic cores 1 and 5 are replaced with the ferrite cores 2, 5 a, and 5 b, and the metal cores 3, 6, which have a higher saturation magnetic flux density than this, 7, the cross-sectional area of the metal core 3 is smaller than the cross-sectional area of the ferrite core 2, the cross-sectional area of the metal cores 6 and 7 is smaller than twice the cross-sectional area of the ferrite core 5 a, and the ferrite core 5 b Since the metal cores 3, 6, and 7 are wound to be smaller than twice the cross-sectional area, the number of turns is the same as in the case of winding around the outer periphery of the ferrite core as in the prior art. The copper loss can be reduced by shortening the total length of the winding 4 and reducing the electrical resistance.

しかも、巻線４を施す金属コア３、６、７の断面積を小さくしているために、巻線のためのスペースを増大させることができ、よって巻線４自体の線径を大きくして一層の電気抵抗の低減効果を得ることも可能になる。この結果、簡易な構造により巻線の銅損４を効果的に低減して大電流化に対応することができる。   Moreover, since the cross-sectional area of the metal cores 3, 6 and 7 to which the winding 4 is applied is reduced, the space for the winding can be increased, and thus the wire diameter of the winding 4 itself is increased. It is also possible to obtain a further effect of reducing electric resistance. As a result, the copper loss 4 of the windings can be effectively reduced with a simple structure to cope with a large current.

さらに、金属コア３、６、７の素材として、金属のうちでも磁心損失が小さいナノ結晶合金、アモルファス、パーマロイ、センダストまたはダストコアを用いているために、銅損の低減とともに、磁心損失の低減も図ることができる。   Furthermore, as the material for the metal cores 3, 6 and 7, among the metals, a nanocrystalline alloy, amorphous, permalloy, sendust or dust core with a small magnetic core loss is used. Can be planned.

なお、第３の実施形態においては、磁性コイル１の金属コア３の外周に、一次側（または二次側）巻線４を施すとともに、フェライトコア２の外周に二次側（または一次側）巻線８を施した場合に付いて説明したが、これに限らず、金属コア３の対向位置に同様に金属コアを配置して、これらの金属コア３に、巻線４，８を巻回してもよい。   In the third embodiment, a primary side (or secondary side) winding 4 is provided on the outer periphery of the metal core 3 of the magnetic coil 1, and a secondary side (or primary side) is provided on the outer periphery of the ferrite core 2. Although the case where the windings 8 are provided has been described, the present invention is not limited to this, and the metal cores are similarly arranged at positions facing the metal cores 3, and the windings 4 and 8 are wound around these metal cores 3. May be.

１、５ 磁性コア
２、５ａ、５ｂ フェライトコア
３、６、７ 金属コア
４、８ 巻線 1, 5 Magnetic core 2, 5a, 5b Ferrite core 3, 6, 7 Metal core 4, 8 Winding

Claims (4)

磁性コアの外周に巻線を施したコイル部品において、
上記磁性コアをフェライトコアおよび金属コアによって口字状に構成し、少なくとも上記金属コアの外周に上記巻線を施すとともに、上記金属コアの断面積を、上記フェライトコアの断面積よりも小さくしたことを特徴とするコイル部品。 In coil parts with windings on the outer periphery of the magnetic core,
The magnetic core is formed in a lip shape by a ferrite core and a metal core, and the winding is applied to at least the outer periphery of the metal core, and the cross-sectional area of the metal core is made smaller than the cross-sectional area of the ferrite core. Coil parts characterized by 磁性コアの外周に巻線を施したコイル部品において、
上記磁性コアを、対向配置された一対の背部と、当該背部の両端部間に配置された一対の外足部と、上記背部の中央部間に配置された中足部とを有する日字状に形成し、上記背部および上記外足部をフェライトコアによって構成するとともに上記中足部を金属コアによって構成し、少なくとも上記金属コアの外周に上記巻線を施すとともに、上記金属コアの断面積を、その両側の上記外足部の合計断面積よりも小さくしたことを特徴とするコイル部品。 In coil parts with windings on the outer periphery of the magnetic core,
The said magnetic core has a pair of back part arrange | positioned oppositely, a pair of outer leg part arrange | positioned between the both ends of the said back part, and the Japanese character shape which has the middle leg part arrange | positioned between the center parts of the said back part And forming the back portion and the outer foot portion by a ferrite core and the middle foot portion by a metal core, applying the winding to at least the outer periphery of the metal core, and reducing the cross-sectional area of the metal core. A coil component characterized in that it is smaller than the total cross-sectional area of the outer legs on both sides thereof. 上記金属コアは、ナノ結晶合金、アモルファス、パーマロイまたはセンダストからなることを特徴とする請求項１または２に記載のコイル部品。   The coil component according to claim 1 or 2, wherein the metal core is made of a nanocrystalline alloy, amorphous, permalloy, or sendust. 上記金属コアは、ナノ結晶合金、アモルファス、パーマロイまたはセンダストの金属磁性粉末をバインダーと混合して加圧成形した圧粉磁心（ダストコア）からなることを特徴とする請求項１または２に記載のコイル部品。   3. The coil according to claim 1, wherein the metal core is formed of a powder magnetic core (dust core) obtained by pressing and molding a nanocrystalline alloy, amorphous, permalloy, or sendust metal magnetic powder with a binder. parts.
JP2015200052A 2015-10-08 2015-10-08 Coil component Pending JP2017073486A (en)

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