JP2017098476A - Coil device and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simplify a manufacturing process of a coil device.SOLUTION: A coil device 10 is composed of a bare conductor on which no coat is formed and includes: a coil 11 having a plurality of winding turn portions 12 and terminal portions to be connected to the outside; a case 40 accommodating the plurality of turn portions 12; and an insulating filling portion 45 disposed between at least the adjacent turn portions 12 and filling the case 40.SELECTED DRAWING: Figure 3

Description

  The technology described herein relates to a coil device.

  An electric junction box such as a DC-DC converter is mounted on a vehicle such as an automobile, and a coil is used as a circuit component of the electric junction box. As for the reactor apparatus of patent document 1, the coil and the core are accommodated in the case. An enamel coating for insulation is formed on the wire conductor constituting the coil, and the coil terminals are joined to the wiring conductor (bus bar) after performing the work of stripping the enamel coating, and the DC conductor It is electrically connected to the primary side of the / DC voltage converter and the semiconductor element of the main circuit.

JP 2012-119545 A

  Here, as shown in Patent Document 1, when the enamel coating for insulation is formed on the coil, it is necessary to remove the enamel coating for the coil terminals, which complicates the manufacturing process. There was a problem.

  The technique described in the present specification has been completed based on the above-described circumstances, and aims to simplify the manufacturing process of the coil device.

  The coil device described in the present specification includes a coil having a plurality of wound portions and a terminal portion connected to the outside, which are formed of a bare conductor with no coating formed thereon, and the plurality of turn portions. A housing case, and an insulating filling portion that is disposed between at least the adjacent turn portions and is filled in the case.

  A method for manufacturing a coil device described in the present specification includes a coil that is formed of a bare conductor without a coating and is wound so as to have a plurality of turn portions, and the plurality of turn portions. A method of manufacturing a coil device including a case, wherein a filling portion is formed by filling the case with an insulating filler so as to be disposed at least between adjacent turn portions.

  According to the above configuration, a coil made of a bare conductor in which no coating is formed in the coil device does not require a step of peeling the coating made of, for example, enamel on the terminal portion connected to the outside. The manufacturing process can be simplified. Here, the coil made of a bare conductor is concerned about the insulation between adjacent turn parts, but according to this configuration, the insulating filling part in the state filled in the case is at least between adjacent turn parts. Therefore, the insulation between adjacent turn parts can be maintained.

The following embodiments are preferable as the embodiments of the technology described in this specification.
An insulating holding member that holds the coil is provided, and the holding member includes a partition plate that partitions the adjacent turn portions.
If it does in this way, between turn parts which adjoin can be reliably insulated by a partition plate.

The coil is an edgewise coil wound so that the short side of the rectangular wire is an inner diameter surface, and the partition plate is wound along the coil.
In this way, the shape of the edgewise coil can be held by the holding member.

  The holding member includes a cylindrical cylindrical portion connected to the inside of the partition plate, has a column portion inserted into the cylindrical portion, and has a magnetic core accommodated in the case. Prepare.

  According to the technique described in this specification, the manufacturing process of a coil apparatus can be simplified.

The perspective view which shows the coil apparatus of Embodiment 1. FIG. Plan view showing coil device AA sectional view of FIG. Front view showing the coil device Rear view showing coil device The perspective view which shows the state by which the holding member was mounted | worn with the coil The top view which shows the state by which the holding member was mounted | worn with the coil BB sectional view of FIG. Front view showing a state where a holding member is attached to the coil Bottom view showing a state where the holding member is mounted on the coil The perspective view which shows a holding member Front view showing the holding member

<Embodiment 1>
The coil apparatus 10 of Embodiment 1 is demonstrated with reference to FIGS.
The coil device 10 according to the present embodiment is provided in, for example, a DC / DC converter of a vehicle such as an electric vehicle or a hybrid vehicle, and can be used as, for example, a choke coil that smoothes an output voltage. Although the coil device 10 can be arranged in an arbitrary direction, the following description will be made assuming that the X direction is right, the Y direction is front, and the Z direction is upward.

(Coil device 10)
As shown in FIG. 3, the coil device 10 includes a coil 11, a holding member 20 that holds the shape of the coil 11, a magnetic core 30, and a case 40 that houses the coil 11, the holding member 20, and the core 30. And a filling portion 45 in a state where the case 40 is filled.

(Coil 11)
The coil 11 is a so-called edgewise coil, which is made of, for example, copper or a copper alloy. As shown in FIGS. 6 and 8, a rectangular wire having a flat rectangular cross section is formed, and the short side has an inner diameter surface and an outer diameter. It is formed by spirally winding so as to be a surface, and is a bare conductor on which a coating such as enamel is not formed. The coil 11 includes a plurality of (four in this embodiment) annular turn portions 12 formed by spirally winding a strip-shaped rectangular wire, and a pair of terminal portions 13 connected to the outside.

  The plurality of turn parts 12 have the same shape (the same inner diameter and outer diameter), are arranged along the axis A1 direction of the turn part 12, and adjacent turn parts 12 along the axis A1 direction are circumferentially arranged. It is lined up. As a whole, the plurality of turn portions 12 allow the coil 11 to be elastically deformed in the direction of the axis A1.

  The pair of terminal portions 13 are both linear and arranged in parallel to each other, are connected to the start and end portions of the plurality of turn portions 12, and are straight along the tangential direction of the inner periphery and outer periphery of the turn portion 12. It extends in a shape. A circular connection hole 14 through which a shaft portion of a bolt as a fastening member (not shown) can be inserted is formed through the tip of the terminal portion 13. The terminal portion 13 is in a bare state where no coating is formed.For example, by fastening with a nut through a shaft portion of a bolt as a fastening member in a connection hole of a mating terminal extending from a bus bar or the like of a circuit board (not shown), The terminal portion 13 and the counterpart terminal are connected.

(Holding member 20)
The holding member 20 is a bobbin made of synthetic resin having insulation properties, and as shown in FIG. 11, a cylindrical tubular portion 21, and a partition plate 22 that protrudes spirally from the outer periphery of the tubular portion 21. It has. The cylindrical portion 21 has a cylindrical shape, and has an inner diameter that allows the column portion 32 of the core 30 to be inserted.

  The partition plate 22 is formed on the outer periphery of the cylindrical portion 21 so as to project in a spiral shape with a substantially constant projection dimension. A space between the start end 22A and the end end 22B of the partition plate 22 and the adjacent partition plate 22 serves as an insertion port when the coil 11 is mounted. Of the partition plate 22, the vicinity of the start end 22 </ b> A and the end 22 </ b> B protrudes in a direction perpendicular to the direction of the axis A <b> 1 with respect to the tubular portion 21, and is formed slightly tapered toward the start end 22 </ b> A and the end 22 </ b> B. Each partition plate 22 is disposed between adjacent turn portions 12, and the projecting dimension thereof is constant over the entire length of the partition plate 22, and is slightly larger than the width of the coil 11 extending in a strip shape.

(Core 30)
The core 30 is formed of a high permeability magnetic material such as ferrite, and is configured by combining a pair of upper and lower divided members 31A and 31B as shown in FIG. Each of the divided members 31A and 31B includes a columnar column 32, a side wall 33 having an inner surface curved in an arc shape, and a plate that supports the coil 11 and the holding member 20 by connecting the column 32 and the side wall 33. Are formed integrally.

(Case 40)
The case 40 is made of an insulating synthetic resin and includes a rectangular tube-shaped rectangular tube portion 41 and a back wall portion 44 that closes the rectangular tube portion 41 as shown in FIGS. Yes. A rectangular opening 42 into which the coil 11 and the holding member 20 can be inserted is formed at the front end portion of the rectangular tube portion 41, and the front end portion of the rectangular tube portion 41 slightly protrudes outward and has a thickness. Has been thickened. On both side walls of the rectangular tube portion 41, a fastening portion 43 for screwing with a screw (not shown) projects. A screw hole through which the shaft portion of the screw is inserted is formed through the fastening portion 43. The back wall portion 44 covers the back surface of the rectangular tube portion 41 without a gap, and irregularities corresponding to the shapes of the turn portion 12 and the partition plate 22 are formed.

(Filling part 45)
The filling portion 45 is filled with a filler so as to fill the gap in the case 40, and as shown in FIG. 3, the gap between the partition plate 22 and the turn portion 12, the turn portion 12 and the partition plate. 22 and the gap between the core 30 and the gap between the core 30 and the case 40. In the present embodiment, for example, an epoxy resin is used as the filler, but is not limited thereto, and other known materials can be used. Further, the filler is a liquid when injected into the case 40. For example, a thermosetting resin that is solidified by heating after injection into the case 40 or a room temperature curable resin that is cured without heating may be used. Further, as the filler, a material having a viscosity that can retain the shape to some extent without being cured after being injected into the case 40 may be used. The viscosity of the filler is such that the liquid filler enters the gap between the coil 11 and the partition plate 22 and the like, and depends on the size of the gap between the coil 11 and the partition plate 22 and the like. A suitable viscous material is used.

Next, assembly of the coil device 10 will be described.
The coil 11 is rotated so that the end portion side of the coil 11 enters the insertion port of the start end 22A or the end end 22B of the partition plate 22, and the entire plurality of turn portions 12 are fitted into the gaps between the spiral partition plates 22. . The coil 11 and the holding member 20 in this state are placed on the lower divided member 31B constituting the core 30, and the upper divided member 31A is fitted and accommodated in the case 40. Next, the case 40 in which the coil 11, the holding member 20, and the core 30 are accommodated is oriented so that the opening 42 faces upward, and a filler is injected by an injection machine (not shown). When the filler is filled to a predetermined depth of the case 40, the injection is finished. When the filler is solidified, the filling portion 45 is formed and the coil device 10 is formed.

According to the present embodiment, the following operations and effects are achieved.
According to the present embodiment, the coil 11 made of a bare conductor on which no coating is formed in the coil device 10 does not require a step of peeling off the coating made of, for example, enamel on the terminal portion 13 connected to the outside. The manufacturing process of the coil device 10 can be simplified. Here, the coil 11 made of a bare conductor has a concern about the insulation between the adjacent turn portions 12 in the wound state. However, according to the present embodiment, the insulation in the state where the case 40 is filled is provided. Since the conductive filling portion 45 is disposed at least between the adjacent turn portions 12, the insulation between the adjacent turn portions 12 can be maintained.

In addition, an insulating holding member 20 that holds the coil 11 is provided, and the holding member 20 includes a partition plate 22 that partitions adjacent turn portions 12.
In this way, the adjacent turn parts 12 can be reliably insulated by the partition plate 22.

The coil 11 is an edgewise coil wound so that the short side of the rectangular wire is the inner diameter surface, and the partition plate 22 is wound along the coil 11.
In this way, the shape of the edgewise coil 11 can be held by the holding member 20.

The holding member 20 includes a cylindrical cylindrical portion 21 connected to the inside of the partition plate 22, has a column portion 32 inserted into the cylindrical portion 21, and is stored in the case 40. A body core 30 is provided.
In this way, the insulation between the coil 11 and the core 30 can be maintained by the cylindrical portion 21 and the filling portion 45.

<Other embodiments>
The technology described in the present specification is not limited to the embodiment described with reference to the above description and the drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) In the above embodiment, the holding member 20 is provided. However, a coil device that does not include the holding member 20 may be used. In this case, for example, the position of the coil 11 may be held by the filling portion 45 in the case 40.

(2) In the above embodiment, the coil device 10 is used for a DC / DC converter of a vehicle, but is not limited thereto, and may be a coil device used for other devices.

(3) In the above embodiment, the whole of the plurality of turn portions 12 and the partition plate 22 are embedded in the filling portion 45, but the present invention is not limited to this, and a part of the plurality of turn portions 12 and the partition plate 22 is the filling portion. It is not embedded in 45 and may be exposed outside.

DESCRIPTION OF SYMBOLS 10: Coil apparatus 11: Coil 12: Turn part 13: Terminal part 20: Holding member 21: Cylindrical part 22: Partition plate 30: Core 32: Column part 40: Case 45: Filling part

Claims (5)

A coil made of a bare conductor with no coating formed thereon, having a plurality of wound turns and a terminal connected to the outside;
A case for accommodating the plurality of turn portions;
A coil device comprising: an insulating filling portion disposed at least between the adjacent turn portions and filled in the case. An insulating holding member for holding the coil;
The coil device according to claim 1, wherein the holding member includes a partition plate that partitions the adjacent turn portions. The coil is an edgewise coil wound so that the short side of the rectangular wire is the inner diameter surface,
The coil device according to claim 2, wherein the partition plate is wound along the coil. The holding member includes a cylindrical cylindrical portion connected to the inside of the partition plate,
4. The coil device according to claim 2, further comprising a pillar portion inserted inside the cylindrical portion, and comprising a magnetic core accommodated in the case. 5. A coil device comprising a bare conductor with no coating formed and wound so as to have a plurality of turn portions, a case for accommodating the plurality of turn portions, and a manufacturing method of a coil device comprising:
A manufacturing method of a coil device, wherein an insulative filler is filled in the case so as to be disposed at least between adjacent turn portions to form a filling portion.

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