JP2017208495A - Common mode filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a common mode filter having such a structure that a lead wire having a rectangular-shaped cross section can be wound by a machine.SOLUTION: A magnetic body core having such a structure that two circular cylinders are concentrically connected, and a first coil and a second coil obtained by winding lead wires having a rectangular-shaped cross section and that have substantially the same dimension and electrical characteristics and that are juxtaposed so that winding parts are adjacent to each other, are covered with an insulation thermoplastic resin to form an outer package. The outer package is heated and compressed by using a mold in a state incorporated in a box-like block 8 and a lid-like block 9, and thereby, an element body is obtained. From slits 91 and 93, ends 31a-34a of the respective lead wires are folded so that their wide faces extend to a mounting surface.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a common mode filter used in a power supply device.

  Conventionally, a common mode filter has been used as a filter for removing common mode noise. Since the common mode filter described in Patent Document 1 has a configuration in which a conducting wire is wound around a toroidal core, the common mode filter has high effective magnetic permeability and can obtain excellent noise removal performance.

JP-A-6-36951

A conducting wire used for a common mode filter for a large current such as a power supply device is preferably a conducting wire having a rectangular cross section capable of securing a large cross-sectional area. However, when a conducting wire is wound around a toroidal core, automatic winding using a machine is difficult. Although it is possible to wind with human hands, it takes time and increases the variation in electrical characteristics.
Then, in view of the said subject, this invention aimed at provision of the common mode filter of the structure which can wind the conducting wire of a cross-sectional rectangular shape with a machine.

  The present invention provides a magnetic core, a first conductive wire and a second conductive wire wound around the magnetic core, a third conductive wire and a fourth conductive wire wound around the magnetic core, A first coil formed by the first and second conductive wires, a second coil formed by the third and fourth conductive wires, the first coil, the second coil, and the magnetic core. And a first electrode and a third electrode, and a second electrode and a fourth electrode, which are arranged so as to be diagonally located at the four corners of the mounting surface of the element body, and the second electrode and the fourth electrode. A common mode filter comprising: a fifth electrode adjacent to the first electrode and the second electrode; and a sixth electrode disposed in the center and adjacent to the third electrode and the fourth electrode. The fourth conductor is a conductor having a rectangular cross section, and the lengths of the first conductor and the third conductor are equal. The lengths of the second conductor and the fourth conductor are equal, and the lengths of the first conductor and the third conductor are longer than the lengths of the second conductor and the fourth conductor, The first conductor and the second conductor are overlapped and fixed in the thickness direction, the third conductor and the fourth conductor are overlapped and fixed in the thickness direction, and the first conductor and the second conductor are fixed. A predetermined distance is provided in the length direction of the conducting wire between the end and the end of the second conducting wire, and a conducting wire is provided between the end of the third conducting wire and the end of the fourth conducting wire. The element body includes the first coil and the second coil so that a winding axis thereof is parallel to the mounting surface, and the element body includes the first coil and the second coil. The first conductor and the sixth electrode disposed on the mounting surface of the first conductor are electrically connected by extending the ends of the first conductors, respectively. The terminal of the second conductor is extended and electrically connected to the fourth electrode and the fifth electrode, respectively, and the terminal of the third conductor is extended and electrically connected to the third electrode and the fifth electrode. And connected to the second electrode and the sixth electrode by extending the ends of the fourth conductors, respectively.

  According to the present invention, it is possible to cope with a large current by using a conducting wire having a rectangular cross section. In addition, since the structure can be wound by a machine, there is little variation in electrical characteristics during mass production.

It is a perspective view explaining the process of winding the 1st coil used in the Example of this invention. It is a perspective view explaining the process of winding the 2nd coil used in the Example of this invention. It is a perspective view explaining the process of inserting a magnetic body core in the 1st coil used in the Example of this invention. It is a perspective view explaining the process of inserting a magnetic body core in the 2nd coil used in the Example of this invention. It is a perspective view when the coil used in the Example of this invention is coated with resin. It is a perspective view explaining the process of sealing the coil used in the Example of this invention to a block. It is a perspective view of the element body of the Example of this invention. It is an external view of the common mode filter of the Example of this invention. 6A is a perspective view of the common mode filter, FIG. 6B is a plan view seen from the side of the common mode filter, and FIG. 6C is a plan view seen from the mounting surface of the common mode filter. FIG. 6D is a plan view seen from the upper surface of the common mode filter.

  Embodiments of the present invention will be described below with reference to the drawings.

  A process of winding the first coil and the second coil will be described with reference to FIGS. 1 and 2. 1A to 1F are perspective views showing a process of winding a first coil used in the common mode filter of the embodiment of the present invention. 2A to 2F are perspective views showing a process of winding a second coil used in the common mode filter of the embodiment of the present invention. The first coil and the second coil are coils having substantially the same dimensions and electrical characteristics. The coil is formed by winding a first conductor, a second conductor, a third conductor, and a fourth conductor having a rectangular cross section using a winding machine (not shown) having a winding axis. The first conductive wire, the second conductive wire, the third conductive wire, and the fourth conductive wire are each made of a wire material to which a film is fused by heating.

  A method for winding the first coil will be described. As shown in FIG. 1A, the winding shaft 2 of the winding machine has a structure in which two cylinders having different outer diameters are concentrically connected. A cylinder with a small diameter is defined as a core 21. Two winding shafts 2 are used, and as shown in FIG. 1 (b), the winding core 21 is disposed so that the tip portions thereof are in contact with each other. And as shown in FIG.1 (c), the wide surface of a conducting wire is made to contact | abut to the core 21 of the winding shaft 2 in the state which accumulated the 1st conducting wire 31 and the 2nd conducting wire 32 in the thickness direction. Of the two superimposed conductors, the inner conductor is the first conductor 31 and the outer conductor is the second conductor 32. The wide surface of the first conducting wire 31 is in contact with the core 21 of the winding shaft 2.

  As shown in FIG.1 (d), the 1st conducting wire 31 and the 2nd conducting wire 32 are wound simultaneously, and the two 1st winding parts 41 juxtaposed in the winding-axis direction are formed. Then, both ends of the first conducting wire 31 and the second conducting wire 32 are shifted in opposite directions along the winding core, and a part of the wide surface of the first conducting wire 31 is placed on the first winding part 41. Make contact. And it winds repeatedly and forms the 2nd winding part 42 on the 1st winding part 41. FIG. The second winding portion 42 is formed in a state where a part of the innermost wide surface is in contact with the first winding portion 41.

  The end 31a of the first conducting wire 31 and the end 32a of the second conducting wire 32 are pulled out from the outer periphery of each second winding portion 42. Since the length of the second conducting wire 32 is slightly shorter than the length of the first conducting wire 31, the end 32 a of the second conducting wire 32 is spaced apart from the end 31 a of the first conducting wire 31 by a predetermined distance. Is located on the winding part 42 side. (FIG. 1 (e)) Then, as shown in FIG. 1 (f), the end 31a of the first conducting wire and the end 32a of the second conducting wire are extended in the vertical direction from the outer periphery of the second winding portion 42. . Then, the first winding part 41, the second winding part 42, the terminal end 31a of the first conducting wire and the terminal end 32a of the second conducting wire are heated to fix the shape, and the coil 4 is obtained.

The second coil is wound in the same procedure.
Two winding shafts 2 shown in FIG. As shown in FIG.2 (b), it arrange | positions so that the front-end | tip part of the core 21 may mutually contact. Then, as shown in FIG. 2C, the wide surface of the conducting wire is brought into contact with the core 21 of the winding shaft 2 in a state where the third conducting wire 33 and the fourth conducting wire 34 are overlapped in the thickness direction. Of the two superimposed conductors, the inner conductor is the third conductor 33 and the outer conductor is the fourth conductor 34. The wide surface of the third conductor 33 is in contact with the core 21 of the winding shaft 2.

  As shown in FIG.2 (d), the 3rd conducting wire 33 and the 4th conducting wire 34 are wound simultaneously, and the two 1st winding parts 51 juxtaposed in the winding-axis direction are formed. Then, both ends of the third conducting wire 33 and the fourth conducting wire 34 are shifted in opposite directions along the winding core, and a part of the wide surface of the third conducting wire 33 is placed on the first winding portion 51. Make contact. And it winds repeatedly and forms the 2nd winding part 52 on the 1st winding part 51. FIG. The second winding part 52 is formed in a state where a part of the innermost wide surface is in contact with the first winding part 51.

  The terminal 33a of the third conductor 33 and the terminal 34a of the fourth conductor 34 are pulled out from the outer periphery of each second winding part 52. Since the length of the fourth conducting wire 34 is slightly shorter than the length of the third conducting wire 33, the end 34 a of the fourth conducting wire 34 is spaced apart from the end 33 a of the third conducting wire 33 by a predetermined distance. Is located on the winding part 52 side. Then, as shown in FIG. 2 (f), the end 33a of the third conducting wire and the end 34a of the second conducting wire are extended vertically from the outer periphery of the second winding portion 52. . And the 1st winding part 51, the 2nd winding part 52, the end 33a of the 3rd conducting wire, and the end 34a of the 4th conducting wire are heated, and shape is fixed, and coil 5 is obtained.

  The process of sealing the coil to the element body will be described with reference to FIGS. FIG. 3 is a perspective view for explaining a step of inserting a magnetic core into the first coil used in the embodiment of the present invention. FIG. 4 is a perspective view illustrating a process of inserting a magnetic core into the second coil used in the embodiment of the present invention. FIG. 5 is a perspective view when the coil used in the embodiment of the present invention is coated with resin. FIG. 6 is a perspective view illustrating a process of sealing the coil used in the embodiment of the present invention in a block.

  The process of inserting the magnetic core 43 into the first coil 4 will be described. The magnetic core 43 has a structure in which two cylinders are connected concentrically. The outer diameters of the respective cylinders are substantially the same as the inner diameters of the first winding part 41 and the second winding part 42. As shown in FIG. 3A, the magnetic core 5 is disposed on both sides of the first coil 4 and is inserted into the air core portion of the first coil 4. As shown in FIG. 3B, the magnetic core 5 fits inside the first coil 4 with almost no gap.

  The process of inserting the magnetic core 53 into the second coil 5 will be described. The magnetic core 53 has the same shape as the magnetic core 43. The outer diameter of each cylinder is substantially the same as the inner diameter of the first winding part 51 and the second winding part 52. As shown in FIG. 4A, the magnetic cores 53 are arranged on both sides of the second coil 5 and inserted into the air core portion of the second coil 5. As shown in FIG. 4B, the magnetic core 53 fits inside the second coil 5 with almost no gap.

  A process of coating the magnetic cores 43 and 53, the first coil 4, and the second coil 5 with resin will be described. A first coil 4 in which the magnetic core 43 is inserted and a second coil 5 in which the magnetic core 53 is inserted into a cylindrical mold (not shown) are connected to the second winding portions 42 and 52. Put them side by side so that they are next to each other. Then, the end 31a of the first conducting wire, the end 32a of the second conducting wire, the end 33a of the third conducting wire, and the end 34a of the fourth conducting wire are drawn out so as to be exposed from the mold, and then insulated from the mold Inject a thermoplastic resin. Then, the resin is cured by heating and taken out from the mold. From the above, as shown in FIG. 5, the exterior body 6 including the magnetic cores 43 and 53, the first coil 4, and the second coil 5 can be obtained. The terminal end 31a of the first conducting wire, the terminal end 32a of the second conducting wire, the terminal end 33a of the third conducting wire, and the terminal end 34a of the fourth conducting wire are respectively exposed and drawn out from the exterior body 6. The terminal ends 31a of the drawn out first conductive wires are located diagonally to each other, and the terminal ends 32a of the respective second conductive wires are located diagonally to each other. Similarly, the end 33a of each drawn out third conductor is located diagonally to each other, and the end 34a of each fourth conductor is located diagonally to each other. Then, the terminal end 31a of the first conductor and the terminal 33a of the third conductor are adjacent to each other, and the terminal 32a of the second conductor and the terminal 34a of the fourth conductor are adjacent to each other.

A process of incorporating the exterior body 6 in the element body 7 will be described. The element body 7 is composed of a box-shaped block 8 and a lid-shaped block 9, and each of the box-shaped block 8 and the lid-shaped block 9 is composed of a thermoplastic sealant containing resin and magnetic powder. .
As shown in FIG. 6A, the box-shaped block 8 has a cubic shape with an open end on the upper surface, and has a space for housing the exterior body 6 therein. The edge surrounding the open end is formed with a recess 81 that fits into the lid-like block.

  The lid-like block 9 has a flat plate shape, and includes a convex portion 91 provided at an end portion and six elongated slits 92 and 93 provided at a central portion. The four slits 92 provided at both ends of the center are provided symmetrically with respect to the center of the lid-like block 9, and the center side of the block 9 is terminated and the outside is opened. In the center of the block 9, two elongated slits 93 are provided. And the convex part 91 provided in both ends fits into the recessed part 81 of the edge which surrounds the opening end of the box-shaped block 8, respectively.

  The outer package 6 in which the terminal end 31a of the first conductor, the terminal end 32a of the second conductor, the terminal 33a of the third conductor, and the terminal 34a of the fourth conductor are drawn right above is formed into a box-shaped block 8. Built in. Then, as shown in FIG. 6B, a lid-like block 9 is covered from above, and the slits 92 and 93 are respectively connected to the first conductor end 31a, the second conductor end 32a, and the third conductor. Pull out the end 33a and the end 34a of the fourth conductor. The terminal end 31a of the first conducting wire is drawn out from the slits 91 and 93 that are located diagonally to each other. Similarly, the terminal end 32a of the second conducting wire, the terminal end 33a of the third conducting wire, and the terminal end 34a of the fourth conducting wire are also drawn out from the slits 91 and 93 that are located diagonally to each other. The leading end 31a of the first conductor, the terminal 32a of the second conductor, the terminal 33a of the third conductor, and the terminal 34a of the fourth conductor are extended so that the wide surface extends to the mounting surface. Bend it.

  A process of forming the element body will be described with reference to FIGS. FIG. 7 is a perspective view of the element body according to the embodiment of the present invention. FIG. 8 is an external view of a common mode filter according to an embodiment of the present invention. 8A shows a perspective view of the common mode filter, FIG. 8B shows a plan view seen from the side of the common mode filter, and FIG. 8C shows a plan view seen from the mounting surface of the common mode filter. FIG. 8D shows a plan view seen from the upper surface of the common mode filter.

The exterior body 6 is heated and compressed using a mold (not shown) in a state where the exterior body 6 is housed in the box-like block 8 and the lid-like block 9 to obtain the element body 7. As shown in FIG. 7, the element body 7 is a cube in which six trapezoids 71 are formed on the mounting surface. Then, as shown in FIG. 8, the first electrode 11, the second electrode 12, the third electrode 13, the fourth electrode 14, the fifth electrode 15, and the sixth electrode 16 are formed on the upper surfaces of the four trapezoids 71, respectively. . The first electrode 11 and the third electrode 13, and the second electrode 12 and the fourth electrode 14 are formed at the four corners of the mounting surface so as to be diagonal to each other. The fifth electrode 15 and the sixth electrode 16 are respectively formed in the center of the mounting surface, the fifth electrode 15 is formed adjacent to the first electrode 11 and the second electrode 12, and the sixth electrode 16 is the third electrode. 13 and the fourth electrode 14 are formed adjacent to each other.
The first electrode and the end 31a are electrically connected, the second electrode and the end 34a are electrically connected, the third electrode and the end 33a are electrically connected, and the fourth electrode and the end 32a are electrically connected. The fifth electrode is electrically connected to the end 32a and the end 33a, and the sixth electrode is electrically connected to the end 31a and the end 34a.
Since the extended surface distance can be increased by the four trapezoids 71, the insulation between the electrodes is high.

As described above, through the process of winding the coil, the process of inserting the magnetic core, the process of coating the coil with resin, the process of incorporating the coil in the element body, and the process of forming the electrode, the common mode filter Can be produced. The common mode filter of the present embodiment uses a conducting wire having a rectangular cross section and can handle a large current. In addition, the common mode filter is easier to manufacture on a machine than a common mode filter using a conventional toroidal core. .
In this embodiment, the lengths of the first conductor and the third conductor are equal, and the lengths of the second conductor and the fourth conductor are equal, but the present invention is not limited to this, and the first conductor and the third conductor are not limited to this. The length of the conducting wire and the lengths of the second conducting wire and the fourth conducting wire may be different. As a result, the first coil and the second coil may have different dimensions and electrical characteristics. In the common mode filter of the present invention, the first conductor and the fourth conductor are electrically connected, and the second conductor and the third conductor are electrically connected. The line length of the electrode is substantially equal to the line length of the third electrode to the fourth electrode.

DESCRIPTION OF SYMBOLS 1 Common mode filter 11 1st electrode 12 2nd electrode 13 3rd electrode 14 4th electrode 15 5th electrode 16 6th electrode 2 Winding shaft 21 Core 31 1st conducting wire 31a 1st conducting wire Terminal 32 of the second conductor 32a Terminal 33 of the second conductor 33 Third conductor 33a Terminal 3 of the third conductor 34 Fourth conductor 34a Terminal 4 of the fourth conductor 4 First coil 41 First winding part 42 Second Winding Part 43 Magnetic Core 5 Second Coil 51 First Winding Part 52 Second Winding Part 53 Magnetic Core 6 Exterior Body 7 Element 71 Trapezoid 8 Box-Shaped Block 81 Recess 9 Lid block 91 Convex part 92 Slit 93 Slit

Claims (6)

A magnetic core;
A first conductor and a second conductor wound around the magnetic core; a third conductor and a fourth conductor wound around the magnetic core;
A first coil formed by the first and second conductors;
A second coil formed by the third and fourth conductors;
An element body containing the first coil, the second coil, and the magnetic core;
The first electrode and the third electrode, the second electrode and the fourth electrode, which are arranged so as to be diagonally located at the four corners of the mounting surface of the element body, are arranged in the center, the first electrode and the second electrode A fifth electrode adjacent to the electrode;
A sixth electrode disposed in the center and adjacent to the third electrode and the fourth electrode;
In the common mode filter with
The first to fourth conductive wires are conductive wires having a rectangular cross section,
The length of the first conductor is longer than the length of the second conductor,
The length of the third conductor is longer than the length of the fourth conductor,
The first conductive wire and the second conductive wire are overlapped and fixed in the thickness direction, and the third conductive wire and the fourth conductive wire are overlapped and fixed in the thickness direction,
Between the terminal end of the first conductor and the terminal of the second conductor, a predetermined interval is provided in the length direction of the conductor,
Between the end of the third conductor and the end of the fourth conductor, a predetermined interval is provided in the length direction of the conductor,
The element body incorporates the first coil and the second coil so that a winding axis thereof is parallel to the mounting surface,
The first electrode and the sixth electrode arranged on the mounting surface of the element body are electrically connected by extending the ends of the first conductors,
Electrically connecting the fourth electrode and the fifth electrode by extending the ends of the second conducting wires,
The third electrode and the fifth electrode are electrically connected by extending the ends of the third conductive wires,
A common mode filter characterized in that the end of the fourth conducting wire is stretched and electrically connected to the second electrode and the sixth electrode, respectively.   2. The common mode filter according to claim 1, wherein the first conductor and the third conductor are equal in length, and the second conductor and the fourth conductor are equal in length.   The center of the first conductor and the center of the second conductor are fixed, and the center of the third conductor and the center of the fourth conductor are fixed. The common mode filter according to claim 2.   The outer surface of the mounting surface of the element body is substantially rectangular, the distance between the end of the first conductor and the end of the second conductor, and the end of the third conductor and the fourth conductor. 4. The common mode filter according to claim 1, wherein an interval between the first end and the end of the common body filter is equal to or shorter than a length of a long side of the rectangle constituting the mounting surface of the element body. 5.   The distance between the end of the first conductor and the end of the second conductor, and the distance between the end of the third conductor and the end of the fourth conductor are determined by mounting the element body. The common mode filter according to any one of claims 1 to 3, wherein the common mode filter has a length equal to or shorter than a short side of a rectangle constituting the surface.   The distance between the end of the first conductor and the end of the second conductor, and the distance between the end of the third conductor and the end of the fourth conductor are the same as the first electrode. The common mode filter according to claim 1, wherein the common mode filter is equal to or shorter than a shortest distance from the third electrode.

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