JP2017107995A - Method for manufacturing coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress generation of abnormal noise due to core vibration.SOLUTION: The method for manufacturing a coil device 10 including a coil 11 formed by winding a conductor and a core 20 of magnetic material inserted into the coil 11, includes: disposing the core 20 in molds 50A, 50B; and performing insert molding to inject an insulating resin, thereby forming an exterior part 30 in which the resin adheres to the core 20.SELECTED DRAWING: Figure 2

Description

  The technology described herein relates to a coil device.

  An electric connection 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 connection box. The reactor apparatus of patent document 1 is accommodated in the case which combined the coil, the bobbin, and the core divided | segmented into two, and is mounted in the motor vehicle.

JP 2012-119545 A

  By the way, when the coil is energized, abnormal noise may be generated due to the vibration of the core caused by magnetostriction generated in the core. In particular, when mounted in a place where quietness is required, such as a vehicle, it is preferable that abnormal noise due to vibration of the core is suppressed.

  The technique described in the present specification has been completed based on the above situation, and aims to suppress the generation of abnormal noise due to the vibration of the core.

A method of manufacturing a coil device described in the present specification is a method of manufacturing a coil device including a coil formed by winding a conductor, and a magnetic core inserted through the coil. By performing insert molding in which an insulating resin is injected by being placed in a mold, an exterior portion is formed in which the resin is in close contact with the core.
According to this configuration, since the exterior portion is in close contact with the core, the vibration of the core due to magnetostriction can be suppressed by the exterior portion, so that abnormal noise is less likely to occur. Therefore, generation | occurrence | production of the noise by the vibration of a core can be suppressed.

The following embodiments are preferable as the embodiments of the technology described in this specification.
The coil is made of a bare conductor having no coating, and has a terminal portion that can be connected to a mating terminal. The insert molding is performed by arranging the coil in the mold together with the core. By forming, the exterior portion formed in close contact with the coil and the core is formed.
In this way, a coil made of a bare conductor without a coating does not require a step of peeling a coating made of, for example, enamel on the terminal portion connected to the counterpart terminal, so that the coil device is manufactured. The process can be simplified. Here, although the coil made of a bare conductor has a concern about insulation, according to this configuration, an insulating resin is provided around the coil conductor by performing insert molding in which the coil is placed in a mold. Therefore, the insulation of the coil can be maintained.

The insert molding is performed in a state where the coil is held by a holding member made of an insulating resin.
If it does in this way, while being able to hold | maintain the shape of a coil with a holding member, it becomes possible to hold | maintain the position of the coil in a metal mold | die.

The coil has a terminal portion connectable with a counterpart terminal, and a insert member for fastening the terminal portion with the counterpart terminal is arranged in the mold to perform the insert molding, The exterior portion is in close contact with the fastening member.
If it does in this way, since a fastening member can be stuck and fixed to an exterior part, an assembly man-hour can be reduced.

  According to the technique described in this specification, generation | occurrence | production of the abnormal noise by the vibration of a core can be suppressed.

The top view which shows the coil apparatus of Embodiment 1. AA sectional view of FIG. BB sectional view of FIG. Front view showing the coil device Left side view showing the coil device Bottom view showing coil device Perspective view showing coil assembly Sectional drawing which shows the state which accommodated the coil assembly in the metal mold | die The perspective view which shows the coil apparatus of Embodiment 2. FIG. Front view showing the coil device Left side view showing the coil device The figure which shows the state in which the coil was hold | maintained at the coil holding member. Sectional drawing which shows the state with which the core was mounted | worn with the coil and the coil 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. 2, the coil device 10 includes a coil 11, a magnetic core 20, and an exterior portion 30 that is in close contact with the coil 11 and the core 20 and covers the coil 11 and the core 20.

(Coil 11)
As shown in FIG. 7, the coil 11 is a so-called edgewise coil, which is made of, for example, copper or a copper alloy, and has a flat rectangular wire having a flat rectangular cross section, and the short side has an inner diameter surface and an outer diameter surface. It is formed by winding in a spiral so as to be a bare conductor without a coating such as enamel. The coil 11 includes a plurality of annular turn portions 12 and a pair of terminal portions 13 connected to the outside. The plurality of turn portions 12 have the same shape (the same inner diameter and outer diameter), are arranged in the vertical direction, and the turn portions 12 adjacent in the vertical direction are continuous in the circumferential direction. The coil 11 can be elastically deformed in the vertical direction as a whole by the plurality of turn portions 12.

  The pair of terminal portions 13 are both linear and arranged in parallel to each other, are connected to each of the plurality of turn portions 12, and extend linearly in the tangential direction of the inner periphery and outer periphery of the turn portion 12. 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 a bare conductor with no coating formed thereon, for example, a nut 44 through a shaft portion of a bolt (not shown) 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). By fastening, the terminal part 13 and the other party terminal are connected.

(Core 20)
The core 20 is made of a magnetic material having high permeability such as ferrite, and is configured by combining a pair of upper and lower divided members 21A and 21B. Each divided member 21 </ b> A, 21 </ b> B supports the coil 11 and the coil holding member 70 by connecting the columnar column 22, the side wall 23 having an inner surface curved in an arc shape, and the column 22 and the side wall 23. A plate-like connection support portion 24, which are integrally formed. A coil assembly 19 is formed by attaching the divided members 21 </ b> A and 21 </ b> B to the coil 11.

(Exterior part 30)
The exterior portion 30 is made of an insulating synthetic resin and is formed by insert molding of the coil assembly 19. As shown in FIGS. 1 and 2, as shown in FIGS. An exterior main body 31 that covers the whole, a filling portion 39 filled in a gap inside the coil 11 and the core 20, and a pair of holding portions 40 that hold a pair of nuts 44 are provided.

  Circular holes 32 are formed in the upper surface portion and the lower surface portion of the exterior body 31. The punching hole 32 is formed by removing a holding pin 52 for positioning and holding the core 20 in the molds 50A and 50B (see FIG. 8) at the time of insert molding. As shown in FIGS. 1 and 3, the exterior body 31 has recesses 33 formed at four corners. The recess 33 has a shape in which the four corners of the exterior body 31 are cut out from the upper end side, and the corners of the inner core 20 are exposed in the recess 33. The position of the lower end 33A of the recess 33 is a position that becomes the mating surface 51 of the molds 50A and 50B. By forming the mating surface 51 at such a position, the misalignment of the divided members 21A and 21B can be suppressed by the molds 50A and 50B during the insert molding.

  The front surface 31A of the exterior body 31 has a flat shape, and the terminal portion 13 and the holding portion 40 protrude from the front surface 31A in a direction perpendicular to the front surface 31A. On both side walls of the exterior body 31, fastening portions 34 for fastening with screws (not shown) protrude. A screw hole 35 through which the shaft portion of the screw is inserted is formed through the fastening portion 34. On the back surface of the exterior part 30, a hollow part 36 and a protruding part 37 corresponding to the shape of the coil assembly 19 are formed. The filling portion 39 enters a gap between adjacent turn portions 12, a gap between the turn portion 12 and the core 20, and a gap between the divided members 21A and 21B.

  The pair of holding portions 40 are provided in front of the exterior main body 31 and are portions where the nuts 44 are integrally fixed by insert molding, and the terminal portions 13 so as to hold the nuts 44 below the terminal portions 13. The pair of holding portions 40 are connected by a plate-like connecting portion 42. Each holding part 40 has insertion holes 41A and 41B through which pins (not shown) for positioning the nuts 44 in the molds 50A and 50B are inserted into the connection holes 14 of the terminal part 13 and the screw holes 45 of the nuts 44, respectively. It is formed in a continuous position. The shaft portion of the bolt to which the nut 44 is fastened is inserted into the insertion holes 41A and 41B.

  A so-called clinch nut is used as the nut 44, and a cylindrical protrusion 46 is formed on the surface of the nut 44. The protrusion 46 is provided at the hole edge of the screw hole 45, and is fitted into the connection hole 14 of the terminal part 13 and is in close contact with the inner surface of the connection hole 14 before insert molding. The outer periphery of the nut 44 has a rectangular shape (polygonal shape) whose rotation within the holding portion 40 is easily restricted.

Next, the manufacturing method of the coil apparatus 10 is demonstrated.
The coil 11 is placed on the lower divided member 21B, and the coil assembly 19 in a state in which the upper divided member 21A is fitted is formed (FIG. 7). Then, the coil assembly 19 and the nut 44 are set in the lower mold 50B, and the upper and lower molds 50A and 50B are fitted (FIG. 8). Then, after the molten resin (for example, epoxy resin) is injected into the upper and lower molds 50A and 50B and the resin is solidified, the upper and lower molds 50A and 50B are removed to form the exterior portion 30 on the coil assembly 19. The coil device 10 (FIG. 1) thus obtained.

According to the present embodiment, the following operations and effects are achieved.
According to the present embodiment, the coil device 10 includes the exterior portion 30 in which the core 20 is placed in the molds 50A and 50B and insert molding is performed in which an insulating resin is injected, and the resin is in close contact with the core 20. Is formed. Thus, since the exterior portion 30 is in close contact with the core 20, vibration of the core 20 due to magnetostriction caused by energization of the coil 11 can be suppressed by the exterior portion 30. Therefore, the generation of abnormal noise due to the vibration of the core 20 can be suppressed. Further, the exterior portion 30 can suppress the generation of abnormal noise due to the vibration of the core due to the magnetic attractive force between the divided members 21A and 21B.

  The coil 11 is made of a bare conductor with no coating, and has a terminal portion 13 that can be connected to a counterpart terminal. In insert molding, the coil 11 is placed in the molds 50A and 50B together with the core 20. Then, by performing insert molding, the exterior portion 30 formed in close contact with the coil 11 and the core 20 is formed.

  In this way, the coil 11 made of a bare conductor without a coating does not require a step of stripping a coating made of, for example, enamel on the terminal portion 13 connected to the counterpart terminal. 10 manufacturing processes can be simplified. Here, although the coil 11 made of a bare conductor has a concern about insulation, according to the present embodiment, by performing insert molding on the coil 11 and the core 20, the periphery of the conductor of the coil 11 is insulated. Since it can be covered with resin, insulation between the adjacent annular turn portions 12 of the coil 11 and between the coil 11 and the core 20 can be maintained.

In addition, the coil 11 is insert-molded by placing a nut 44 (fastening member) for fastening the terminal portion 13 with the mating terminal in the molds 50A and 50B, so that the exterior portion 30 is in close contact with the nut 44. Form.
If it does in this way, since nut 44 can be stuck and fixed to exterior part 30, it can reduce an assembly man-hour.

<Embodiment 2>
Next, Embodiment 2 will be described with reference to FIGS. In the following, the same components as those of the first embodiment are denoted by the same reference numerals and description thereof is omitted.
As shown in FIG. 9, the coil device 60 of the second embodiment is different from the first embodiment in that the holding portion 40 that holds the nut 44 is not formed, and the terminal portion 13 extends from the front surface 31 </ b> A of the exterior body 31. The whole is exposed.

<Embodiment 3>
A third embodiment will be described with reference to FIGS. In the third embodiment, the exterior portion 30 is formed in a state where the coil 11 is held by the coil holding member 70. The same components as those in the above embodiment are denoted by the same reference numerals and description thereof is omitted.
As shown in FIG. 12, the coil holding member 70 is a bobbin made of synthetic resin having insulation properties, and has a cylindrical tubular portion 71 and a partition plate 72 that protrudes spirally from the outer periphery of the tubular portion 71. And. The cylindrical portion 71 has a cylindrical shape, and the column portion 22 of the core 20 is inserted therethrough.

  The partition plate 72 is formed on the outer periphery of the cylindrical portion 71 so as to project in a spiral shape with a substantially constant projecting dimension. A space between the start end 72A and the end end 72B of the partition plate 72 and the adjacent partition plate 72 serves as an insertion port when the coil 11 is rotated and mounted. As shown in FIG. 13, each partition plate 72 is arranged between adjacent turn portions 12, and the projecting dimension is constant over the entire length of the partition plate 72 and is slightly larger than the width of the coil 11. Has been.

  The end portion side of the coil 11 is inserted into the insertion port of the partition plate 72, and the coil 11 is rotated a plurality of times to fit the entire plurality of turn portions 12 into the gaps between the partition plates 72. The coil 11 in this state is placed on the lower split member 86B constituting the core 85, and the coil assembly 87 in a state where the upper split members 86A and 86B are fitted together is formed. And coil apparatus is formed by accommodating the coil assembly 19 in metal mold | die 50A, 50B, and performing insert molding.

According to the third embodiment, insert molding is performed in a state where the coil 11 is held by the coil holding member 70 made of an insulating resin.
If it does in this way, while being able to hold | maintain the shape of the coil 11 with the coil holding member 70, it will become possible to hold | maintain the position of the coil 11 in metal mold | die 50A, 50B.

<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 said embodiment, although the coil apparatus 10 was used for the DC / DC converter of a vehicle, it is not restricted to this, It is good also as a coil apparatus used for another apparatus etc.

(2) The resin forming the exterior portion 30 is an epoxy resin, but is not limited thereto, and other materials may be used.
(3) Although the holding part 40 of Embodiment 1 was set as the structure which hold | maintains the nut 44, it is not restricted to this, The head part of a volt | bolt is formed integrally with a holding part by insert molding, and it is a nut of another member. The terminal part 13 and the mating terminal may be fastened.

(4) The protruding portion 46 of the nut 44 may be press-fitted into the connection hole 14 of the terminal portion 13.

DESCRIPTION OF SYMBOLS 10,60: Coil apparatus 11: Coil 13: Terminal part 20, 85: Core 30: Exterior part 31: Exterior body 39: Filling part 40: Holding part 44: Nut (fastening member)
50A, 50B: Mold 70: Coil holding member

Claims (4)

A coil formed by winding a conductor;
A magnetic core inserted into the coil, and a manufacturing method of a coil device comprising:
A method for manufacturing a coil device, comprising forming an exterior portion in which the resin is in close contact with the core by performing insert molding in which an insulating resin is injected by placing the core in a mold. The coil is made of a bare conductor without a coating, and has a terminal portion that can be connected to a counterpart terminal,
2. The coil according to claim 1, wherein the insert molding forms the exterior portion formed in close contact with the coil and the core by arranging the coil in the mold together with the core and performing the insert molding. Device manufacturing method. The manufacturing method of the coil apparatus of Claim 2 which performs the said insert molding in the state hold | maintained at the holding member which consists of insulating resin. The coil has a terminal portion connectable with a counterpart terminal, and a insert member for fastening the terminal portion with the counterpart terminal is arranged in the mold to perform the insert molding, The manufacturing method of the coil apparatus as described in any one of Claim 1 thru | or 3 which forms the said exterior part closely_contact | adhered to a fastening member.

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