JP2018085410A - Transformer device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a transformer device capable of improving the ease of core assembling.SOLUTION: The transformer device includes: a first coil part formed on a base plate with a conductor patten; a second coil part including an annular upper ring arranged on a top surface side of the base plate with a conductor coil covered with an insulating resin, and an annular lower ring arranged on a bottom surface side of the base plate with a conductor coil covered with an insulating resin; and a pair of an upper core part and a lower core part which form a closed magnetic circuit by sandwiching the first coil part and the second coil part from both surfaces of the base plate. An upper guide part is formed on the upper ring of the second coil part by causing the upper core part to be fitted in and bringing about the fitted-in upper core part into contact with a side face to perform positioning, and a lower guide part is formed on the lower ring of the second coil part by causing the lower core part to be fitted in and bringing about the fitted-in lower core part into contact with the side face to perform positioning and hold the lower core part by a claw part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a transformer device.

  For example, Patent Document 1 discloses a transformer device having a structure in which a substrate on which a coil is mounted is sandwiched between a top surface and a bottom surface of a substrate by a core.

Japanese Patent Laying-Open No. 2015-026867

  The conventional transformer device described in Patent Document 1 employs a structure in which a core is divided into two parts having a pair of upper and lower sides. For this reason, in the assembly work of the transformer device, for example, when assembling the lower core portion arranged on the lower surface side of the substrate, it is necessary to invert the substrate and visually position the lower core portion, There is a problem that work is troublesome, for example, it is necessary to continue to support the assembled lower core part with a finger until the upper core part arranged on the upper surface side of the substrate is assembled.

  Thus, in a transformer device that employs a structure in which the core is divided into two parts, a pair of upper and lower parts, there is room for improvement in terms of ease of assembly of the core.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a transformer device that can improve the ease of assembly of the core.

  In order to solve the above-described problems, a transformer device according to one embodiment of the present invention includes a first coil portion formed by winding a conductor pattern on a substrate one or more times in a planar shape, and winding a conductor plate one or more times. The coil formed in this way is covered with an insulating resin, and is formed by winding the conductor plate at least once with an annular upper ring disposed on the upper surface side of the substrate so that the first coil portion and the winding core coincide with each other. A second coil portion including a first coil portion and an annular lower ring disposed on the lower surface side of the substrate so as to coincide with the winding core, and both surfaces of the substrate. A pair of upper and lower core portions sandwiching the first coil portion and the second coil portion to form a closed magnetic path, and the upper core portion is fitted into the upper ring of the second coil portion The upper guide which positions the fitted upper core part in contact with the side surface The lower guide is inserted into the lower ring of the second coil portion, and the lower core portion that is fitted is brought into contact with the side surface for positioning and held by the claw portion. A portion is formed.

  In this aspect of the present invention, the lower core portion is fitted into the lower ring of the second coil portion, and the fitted lower core portion is positioned in contact with the side surface and is held by the claw portion. A lower guide portion is formed.

  By the action of the side surface of the lower guide portion, positioning can be performed by simply fitting the lower core portion into the lower ring of the second coil portion at the correct position without looking at the lower surface side of the substrate. Therefore, it is not necessary to invert the substrate and the ease of assembling the lower core portion is improved.

  Further, the lower core portion fitted into the lower ring of the second coil portion can be held in a state of being fitted by the action of the claw portion of the lower guide portion. For this reason, it is possible to prevent the lower core portion from falling in the vertical direction, and it is necessary to continue to support the lower core portion with fingers or the like until the upper core portion arranged on the upper surface side of the substrate is fitted. This eliminates the ease of assembling the lower core part.

  Furthermore, according to one aspect of the present invention, the upper core portion is fitted into the upper ring of the second coil portion, and an upper guide portion is formed that positions the fitted upper core portion in contact with the side surface. .

  By the action of the side surface of the upper guide portion, the upper core portion can be easily fitted into the upper ring of the second coil portion at the correct position for positioning. Therefore, it becomes easy to align the upper core portion and the lower core portion, and the ease of assembling the upper core portion is improved.

  As described above, according to the transformer device of the present invention, the ease of assembling the core can be improved.

Exploded view of components of transformer device according to one embodiment of the present invention The figure explaining the detailed structure of the 2nd coil part shown in FIG. The perspective view which shows the transformer apparatus of the semi-assembled state mounted in the board | substrate The figure which looked at the assembly procedure of a transformer apparatus from the A arrow direction in FIG. The figure which looked at the assembly procedure of a transformer apparatus from the A arrow direction in FIG. The figure which looked at the assembly procedure of a transformer apparatus from the A arrow direction in FIG. The figure which looked at the assembly procedure of a transformer apparatus from the A arrow direction in FIG. The figure which looked at the assembly procedure of a transformer apparatus from the A arrow direction in FIG.

[Overview]
The transformer device of the present invention has a structure in which a substrate on which a coil is mounted is sandwiched between cores from both sides, and a guide for determining a position where the lower core is fitted into a resin-molded component placed on the lower surface side of the substrate. And a claw for holding the fitted lower core in that state. By the action of the guide and the claw, the lower core can be easily fitted into the lower surface side of the substrate at the correct position without bothering the lower surface side of the substrate during assembly of the transformer device.

[Structure of each component]
First, with reference to FIG. 1 and FIG. 2, each component which forms the transformer apparatus 1 which concerns on one Embodiment of this invention is demonstrated.

  FIG. 1 is a diagram for explaining the structure of a transformer device 1 according to an embodiment of the present invention by developing component parts of the device. The transformer device 1 illustrated in FIG. 1 includes components of a substrate 10 on which a first coil portion 11 is formed, a second coil portion 20, an upper core portion 30, and a lower core portion 40. FIG. 2 is a diagram illustrating a more detailed structure of the second coil unit 20 in FIG.

  In the transformer device 1 according to the present embodiment, the component parts of the second coil unit 20, the upper core unit 30, and the lower core unit 40 are respectively arranged in the order of the arrow numbers from the direction of the arrows shown in FIG. It is formed by being assembled to (first coil part 11). This assembly method will be described later.

  The transformer device 1 assembled in this way is an element having a structure in which the first coil portion 11 and the second coil portion 20 are magnetically coupled via the upper core portion 30 and the lower core portion 40.

-Substrate 10 and first coil part 11
The substrate 10 is a printed circuit board on which a conductor pattern that circulates electricity is printed, and a predetermined electrical circuit is configured by wiring-connecting mounted components and the like with the conductor pattern. The substrate 10 may have a multilayer structure or a single layer structure.

  The board 10 has an insertion hole 12a through which a middle leg portion 40a, which will be described later, is inserted, an insertion hole 12b through which the outer leg portion 40b of the lower core portion 40 is inserted, and an outer leg of the lower core portion 40. Insertion holes 12c through which the portion 40c is inserted are provided.

  In addition, a spiral conductor pattern is formed around the insertion hole 12a of the substrate 10 by being wound one or more times in a planar shape. When the substrate 10 has a multilayer structure, a spiral conductor pattern may be formed in each layer. The first coil portion 11 having the spiral conductor pattern constitutes a high-voltage coil in the transformer device 1.

  Further, the substrate 10 is provided with a slit 13 into which a connecting portion 24c of the second coil portion 20 described later is inserted. The slit 13 is positioned so that the winding core of the first coil portion 11 and the winding core of the second coil portion 20 coincide with each other by inserting and fitting the connecting portion 24c until it comes into contact with the back end portion 13w. It is formed so that it can be easily realized.

  Furthermore, screw holes 14n for fixedly connecting the first connection terminal 21t and the second connection terminal 22t of the second coil part 20 in which the connecting part 24c is inserted into the slit 13 to the board 10 and the board 10 and 15n are provided respectively.

Second coil unit 20
The second coil unit 20 constitutes a low voltage side coil in the transformer device 1. As shown in FIG. 2, the second coil portion 20 has a structure in which a conductor portion in which two coils 21 and 22 are connected by a connecting portion 23 is covered with an insulating resin (insulating resin) 24 ( Resin mold structure).

  Each of the coil 21 and the coil 22 is an air-core coil formed by winding a conductor plate such as a rectangular copper wire once (edgewise winding). The coil 21 and the coil 22 are formed with the same coil inner diameter and coil outer shape. The coil 21 and the coil 22 are electrically connected to each other at a connecting portion 23 so that both the winding cores coincide with each other and at a predetermined interval and substantially in parallel. The predetermined interval is designed to have an arbitrary dimension capable of providing a predetermined gap 24g between an upper ring 24u and a lower ring 24d covered with an insulating resin 24 described later.

  A first connection terminal 21 t extending to the outside of the insulating resin 24 is connected to the coil 21. The first connection terminal 21t is provided with a screw hole 21n. The coil 22 is connected to a second connection terminal 22t extending outside the insulating resin 24. A screw hole 22n is provided in the second connection terminal 22t.

  The coil 21 is covered with an insulating resin 24 with a predetermined thickness around the coil 21, thereby forming an annular upper ring 24u having a through hole on the inner diameter side of the coil. The periphery of the coil 22 is covered with an insulating resin 24 with a predetermined thickness, thereby forming an annular lower ring 24d having a through hole on the inner diameter side of the coil. Further, the connecting portion 23 that connects the coil 21 and the coil 22 is also covered with an insulating resin 24 with a predetermined thickness, thereby forming a connecting portion 24c. The coil 21 and the coil 22 are molded such that a predetermined gap 24g is formed between the upper ring 24u and the lower ring 24d. The predetermined gap 24g is designed to have a dimension (more than the thickness of the substrate 10) in which the substrate 10 can be inserted. Further, the connecting portion 23 is molded so that the connecting portion 24 c has a thickness equal to or smaller than the width of the slit 13 provided in the substrate 10.

  On the surface of the upper ring 24u opposite to the gap 24g, a pair of V-shaped upper guide portions 24ur that are positioned by fitting the upper core portion 30 are provided upright. The upper guide portion 24ur is shaped like the outer shape of the upper core portion 30, and is formed in a shape in which the opposite inner side surfaces abut on the side surfaces of the upper core portion 30. Note that the upper guide portion 24ur may not have a vertical slit as shown in FIG.

  In addition, a pair of V-shaped lower guide portions 24dr are provided upright on the surface of the lower ring 24d opposite to the gap 24g to perform positioning by fitting the lower core portion 40 therein. The lower guide portion 24dr is shaped like the outer shape of the lower core portion 40, and is formed in a shape in which the opposite inner side surfaces are in contact with the side surfaces of the lower core portion 40. More specifically, the lower guide portion 24dr includes an insertion hole provided in the substrate 10 with the middle leg portion 40a, the outer leg portion 40b, and the outer leg portion 40c of the lower core portion 40 fitted along the side surface. 12a, the insertion hole 12b, and the insertion hole 12c are erected at positions where they can be guided.

  Further, the lower guide portion 24dr is provided with a claw portion 24dt using, for example, a snap fit structure that can hold the lower core portion 40 fitted in the lower guide portion 24dr in a fitted state. ing. The claw portions 24dt illustrated in FIG. 2 are provided at two locations on each of the lower guide portions 24dr. As shown in FIG. 2, the claw portion 24dt extends from the lower end portion of the lower guide portion 24dr, and protrudes inward from the position of the lower end portion of the lower guide portion 24dr where there is an opposing guide portion. The holding part h and the taper part t which becomes thin gradually toward the front-end | tip from the protrusion end part of this holding part h are provided. The distance from the surface of the lower ring 24d to the holding portion h of the claw portion 24dt is set to be equal to or greater than the thickness of the main body portion 40p of the lower core portion 40 described later.

  The shape, position, and number of the claw portions 24dt provided in the lower guide portion 24dr are not limited to the drawings. If the lower core portion 40 fitted into the lower guide portion 24dr has a function capable of being held in the fitted state, the claw portions 24dt other than the shape, position, and number illustrated in the drawing are lowered. You may provide in the side guide part 24dr.

  Moreover, the above-mentioned upper guide part 24ur is erected at a location where the horizontal positions of the upper core part 30 and the lower core part 40 fitted into the second coil part 20 can be aligned. More specifically, the upper guide portion 24ur is erected at a position that coincides with the lower guide portion 24dr in the axial direction of the second coil portion 20.

  In the example of FIG. 2, the example in which the coil 21 and the coil 22 are formed by winding the conductor plate once has been described. However, the coil 21 and the coil 22 may be formed by winding the conductor plate two or more times, or the coil 21 and the coil 22 may have different numbers of windings.

-Upper core part 30 and lower core part 40
The upper core portion 30 is a so-called I-shaped flat plate having a butterfly shape in plan view, which is made of a magnetic material such as a ferrite material. The upper core portion 30 is formed such that the center portion of one side pair is recessed so as to be fitted into a pair of upper guide portions 24ur provided upright on the surface of the upper ring 24u of the second coil portion 20.

  The lower core portion 40 is formed of a magnetic material such as a ferrite material, for example, and has a flat plate-like main body portion 40p having a butterfly shape in plan view, an intermediate leg portion 40a, an outer leg portion 40b, and an outer leg portion 40c. A so-called E-type core. The main body portion 40p is formed such that the center portion of one side pair is recessed so as to be fitted into a pair of lower guide portions 24dr provided upright on the surface of the lower ring 24d of the second coil portion 20. The outer leg portion 40b is erected so that it can be inserted into the insertion hole 12b of the substrate 10 at one end portion in the longitudinal direction of the main body portion 40p. The outer leg portion 40c is erected on the other end portion in the longitudinal direction of the main body portion 40p so as to be inserted into the insertion hole 12c of the substrate 10. The middle leg portion 40a is erected between the outer leg portion 40b and the outer leg portion 40c so as to be inserted into the insertion hole 12a of the substrate 10. The middle leg portion 40a, the outer leg portion 40b, and the outer leg portion 40c have the same height from the main body portion 40p and have end faces formed in parallel with the main body portion 40p.

  The pair of the upper core portion 30 and the lower core portion 40 are formed by joining the end surfaces of the respective leg portions of the lower core portion 40 to one plane of the upper core portion 30 so that the middle leg portion 40a and the outer leg portion 40b are joined. The middle leg portion 40a and the outer leg portion 40c form a closed magnetic circuit (closed magnetic path) through which the magnetic flux penetrating the winding of the second coil portion 20 and the winding of the first coil portion 11 passes.

  The shape of the upper core portion 30 may be an E shape having a flat plate-like main body portion, a middle leg portion standing up from the main body portion, and two outer leg portions, similarly to the lower core portion 40. Absent.

[Assembly method of each component]
Next, with reference to FIGS. 1, 3, and 4 </ b> A to 4 </ b> E, a procedure for assembling each component to form the transformer device 1 according to the present embodiment will be described.

  First, the second coil portion 20 is assembled to the substrate 10 from the direction indicated by the arrow (1) in FIG. At this time, the connecting portion 24c is inserted into the slit 13 while the substrate 10 is inserted into the gap 24g between the upper ring 24u and the lower ring 24d. The second coil part 20 is inserted to a position where the connecting part 24 c contacts the end part 13 w at the back of the slit 13. The assembled state at this time is shown in FIG.

  By this assembly, the upper ring 24u of the second coil part 20 is arranged on one surface side (upward direction of the drawing) of the substrate 10 with the first coil part 11 aligned with the winding core, and the lower side of the second coil part 20 The ring 24d is disposed on the other surface side of the substrate 10 (downward in the drawing) with the first coil portion 11 and the winding core aligned. That is, the second coil portion 20 is positioned with respect to the substrate 10 in a state where the winding core of the first coil portion 11 formed on the substrate 10 and the winding core of the second coil portion 20 coincide with each other. Further, the screw holes 14n and 15n provided in the substrate 10 and the screw holes 21n and 22n provided in the first connection terminal 21t and the second connection terminal 22t of the second coil portion 20 are coincident with each other, and can be screwed. It becomes.

  Next, the substrate 10 on which the second coil unit 20 is assembled from the direction indicated by the arrow (2) in FIG. 1, that is, from the lower ring 24d side of the second coil unit 20 (see FIG. 3 state).

  More specifically, as shown in FIG. 4A, the side surface of the lower core portion 40 is connected to the claw portion 24dt along the inner side surface of the pair of lower guide portions 24dr erected on the lower ring 24d. Incorporated while spreading. As shown in FIG. 4B, the lower core portion 40 is fitted into the lower guide portion dr with each leg portion penetrating the substrate 10, and the bottom surface of the lower core portion 40 is held by the claw portion 24dt. Held by part h.

  Next, as shown in FIG. 4C, the transformer device 1 in a semi-assembled state in which the lower core portion 40 is held by the claw portion 24dt is placed on an installation surface of a predetermined casing 100 such as a mounting destination. In this placement, since the lower core portion 40 is held by the claw portion 24dt, the operation becomes easy.

  Finally, the upper coil portion 30 is placed on the installation surface of the housing 100 from the direction indicated by the arrow (3) in FIG. 1, that is, from the upper ring 24 u side of the second coil portion 20. 20 and the lower core portion 40 are fitted into the substrate 10 assembled thereto.

  More specifically, as shown in FIG. 4D, the side surface of the upper core portion 30 is fitted along the inner side surface of the pair of upper guide portions 24ur provided upright on the upper ring 24u. 4E, the upper core portion 30 is fitted into the upper guide portion 24ur, and the horizontal alignment between the upper core portion 30 and the lower core portion 40 is completed.

  Accordingly, the insertion hole 12a, the through hole of the first coil part 11, and the through hole of the second coil part 20 are inserted, and the first coil part 11 and the second coil part 20 are sandwiched from both sides of the substrate 10. Thus, the end surfaces of the middle leg portion 40 a, the outer leg portion 40 b, and the outer leg portion 40 c of the lower core portion 40 are joined to one plane of the upper core portion 30. Therefore, a closed magnetic path that magnetically couples the first coil portion 11 and the second coil portion 20 can be formed by the pair of the upper core portion 30 and the lower core portion 40.

[Operations and effects of the embodiment]
As described above, according to the transformer device 1 according to the embodiment of the present invention, the lower core portion 40 is fitted into the lower ring 24d of the second coil portion 20, and the lower core portion 40 thus fitted is fitted. A lower guide portion 24dr that is held by the claw portion 24dt and is positioned by contacting the surface with the side surface is formed.

  By the action of the side surface of the lower guide portion 24dr, the lower core portion 40 can be easily fitted into the lower ring 24d of the second coil portion 20 at the correct position without looking at the lower surface side of the substrate 10 for positioning. Can be done. Therefore, it is not necessary to invert the substrate 10 for example. Further, since the lower core portion 40 is positioned in the horizontal direction by the lower guide portion 24dr, it is not necessary to provide a complicated structure for alignment on the installation surface of the housing 100 such as a mounting destination.

  By the action of the claw portion 24dt of the lower guide portion 24dr, the lower core portion 40 fitted into the lower ring 24d of the second coil portion 20 can be held in the fitted state. For this reason, it is possible to prevent the lower core portion 40 from falling in the vertical direction, and for example, the lower core portion 40 can be held with a finger or the like until the upper core portion 30 disposed on the upper surface side of the substrate 10 is fitted. There is no need to continue to support. Therefore, the lower core portion 40 can be transported to the installation surface of the housing 100 such as a mounting destination without dropping.

  Further, according to the transformer device 1 according to the embodiment of the present invention, the upper core portion 30 is fitted into the upper ring 24u of the second coil portion 20, and the fitted upper core portion 30 is brought into contact with the side surface. Thus, an upper guide portion 24ur for positioning is formed.

  By the action of the side surface of the upper guide portion 24ur, the upper core portion 30 can be easily fitted into the upper ring 24u of the second coil portion 20 at the correct position for positioning. Therefore, alignment of the upper core part 30 and the lower core part 40 becomes easy.

  From the above, the ease of assembling the upper core portion 30 and the lower core portion 40 to the substrate 10 (first coil portion 11) and the second coil portion 20 is improved.

  Furthermore, according to the transformer device 1 according to the embodiment of the present invention, the lower core portion 40 is an E-type core. Thereby, the end surface of each leg part of the lower core part 40 can be protruded from the surface of the substrate 10 in a state where the lower core part 40 is fitted into the lower ring 24 d of the second coil part 20. Therefore, when the upper core part 30 is fitted into the upper ring 24u of the second coil part 20, it is possible to suppress the possibility that foreign matter is mixed (sandwiched) between the upper core part 30 and the lower core part 40. Moreover, the presence or absence of foreign matter between the upper core portion 30 and the lower core portion 40 can be easily found visually (improves visibility).

  From the above, the quality of the transformer device 1 in which the substrate 10 (first coil unit 11), the second coil unit 20, the upper core unit 30, and the lower core unit 40 are assembled in the above-described procedure is improved.

  In the transformer device 1 according to the embodiment of the present invention, the annular second coil portion 20 in which the conductor portion is covered with the insulating resin 24 is used. Thereby, the insulation performance of the 1st coil part 11 and the 2nd coil part 20 is securable. Moreover, since the lower core part 40 which is a magnetic core can be inserted and fixed using the through-hole of the 2nd coil part 20 after resin molding as a bobbin, it becomes unnecessary to prepare a bobbin as another component. Therefore, the number of parts of the transformer device 1 can be reduced, and the number of parts assembling steps can be reduced.

  The transformer device of the present invention is useful when it is desired to improve the ease of assembly of the core.

DESCRIPTION OF SYMBOLS 1 Transformer apparatus 10 Board | substrate 11 1st coil part 12a-12c Insertion hole 20 2nd coil part 21, 22 Coil 24 Insulating resin 24u Upper ring 24d Lower ring 24ur Upper guide part 24dr Lower guide part 24dt Claw part 30 Upper core Part 40 Lower core part 40a-40c Leg part

Claims (1)

A first coil portion formed by winding a conductor pattern on a substrate one or more times in a plane;
A coil formed by winding the conductive plate once or more is covered with an insulating resin, and an annular upper ring disposed on the upper surface side of the substrate with the first coil portion aligned with the winding core; A coil formed by winding the conductor plate at least once is covered with an insulating resin, and an annular lower ring disposed on the lower surface side of the substrate with the first coil portion and the winding core aligned. A second coil part including:
A pair of upper and lower core portions that form a closed magnetic path by sandwiching the first coil portion and the second coil portion from both sides of the substrate,
In the upper ring of the second coil part, the upper core part is fitted, and an upper guide part is formed that positions the fitted upper core part in contact with a side surface,
The lower guide portion is fitted into the lower ring of the second coil portion, and is positioned by bringing the fitted lower core portion into contact with the side surface and held by a claw portion. Is formed,
A transformer device.

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