JP2020202215A - Reactor - Google Patents

Abstract

To improve the workability of assembling a coil to a core in a reactor.SOLUTION: A coil 12 constituting a reactor 10 includes a first end portion 18 extending radially outward from the outer peripheral portion of an upper layer 22, and a second end portion 20 extending radially outward from the outer peripheral portion of a lower layer 24. The first and second end portions 18 and 20 extend so as to intersect with each other when viewed from the axial direction of the coil 12 to form an intersection portion 26, and the first end portion 18 is bent in a crank shape from the upper layer 22 on the upper side in the axial direction to the lower side, and the second end portion 20 is bent in a crank shape from the lower layer 24 on the lower side in the axial direction to the upper side. A contact portion 28 is formed in which the first end portion 18 and the second end portion 20 intersect in the vertical direction and the bent portion of the first end portion 18 and the bent portion of the second end portion 20 are in surface contact with each other.SELECTED DRAWING: Figure 1

Description

The present invention relates to a reactor in which both ends of a coil formed by α-winding are brought into contact with each other and taken out to the outside.

Conventionally, a reactor having a coil wound in two stages by α winding and a set of cores in which the coil is housed has been known. As disclosed in Patent Document 1, this reactor is a first winding portion and a second winding portion in which a coil having conductivity and wide in the height direction is wound in two stages and in an annular shape by α winding. The first winding portion and the second winding portion are housed inside the core in a state of being connected to each other on the inner peripheral side.

Then, one end and the other end in the first and second winding portions are arranged so as to be up and down, respectively, and are pulled out from the opening opened to the outside of the core.

Japanese Unexamined Patent Publication No. 2014-33037

However, since the force (springback) that tries to return to the original state due to elastic deformation acts outward in the radial direction of the wound coil as described above, for example, the first and second wound coils are composed of the wound coil. When assembling the winding portion into the core, it is necessary for the operator to perform the work while suppressing the expansion of the coil in the outer peripheral direction, and it is necessary to assemble the ends of the coils at positions corresponding to the drawer grooves. Therefore, there is a problem that the assembly workability is poor.

The present invention has been made in consideration of the above problems, and an object of the present invention is to provide a reactor capable of improving the workability of assembling a coil with respect to a core.

In order to achieve the above object, the aspect of the present invention has the first and second winding layers having two stages in the axial direction, and the first and second winding layers are wound around the bobbin by α winding. In a reactor provided with a coil and a core in which the coil is housed together with a bobbin, the first winding layer is arranged in the upper axial direction and the second winding layer is arranged in the lower axial direction.
The first coil terminal extending radially outward from the outermost peripheral portion of the first winding layer and being pulled out from the opening of the core,
A second coil terminal that extends radially outward from the outermost peripheral portion of the second winding layer and is drawn out from the opening of the core.
An intersection between the tip of the first coil terminal and the second coil terminal and the outermost peripheral portion so as to partially overlap in the axial direction of the coil.
With
The first coil terminal includes a first extending portion that is bent and extends from an axial upper stage to an axial lower stage from the intersection to the tip, and the second coil terminal is a shaft from the intersection to the tip. A second extending portion that is bent and extends from the lower stage in the direction to the upper stage in the axial direction is provided.

According to the present invention, the first and second winding layers include a coil wound around a bobbin by α winding, and a core in which the coil is housed, and this coil is provided from the outermost peripheral portion of the first winding layer. The first coil terminal that extends radially outward and is drawn out from the opening of the core, and the first coil terminal that extends radially outward from the outermost peripheral portion of the second winding layer and is pulled out from the opening. It has a second coil terminal and an intersection formed between the tips of the first and second coil terminals and the outermost peripheral portion so as to partially overlap in the axial direction of the coil.

The first coil terminal includes a first extending portion that is bent from the upper portion in the axial direction to the lower stage in the axial direction from the intersection to the tip, and the second coil terminal extends from the intersection to the tip. It is provided with a second extending portion that is bent and extends from the lower stage in the axial direction to the upper stage in the axial direction.

Therefore, since the first coil terminal and the second coil terminal are formed so as to intersect in the vertical direction by the first and second extending portions formed between the intersection and the tip, the first and second coil terminals are formed. When the springback acts on the second coil terminal, the first coil terminal and the second coil terminal provided so as to intersect with each other move in the direction of approaching each other and come into contact with each other.

As a result, even when the wound coils (first and second winding layers) try to expand radially outward by springback, the first coil terminal and the second coil terminal are kept in contact with each other. Since the spread of the coil can be suitably regulated, the coil can be easily and surely assembled to the core as compared with the conventional reactor which requires the operator to assemble while suppressing the springback of the coil. Workability can be improved.

According to the present invention, the following effects can be obtained.

That is, the first and second coil terminals extending radially outward from the outermost peripheral portion of the first and second winding layers are partially located between the respective tips and the outermost peripheral portions in the axial direction of the coil. The first coil terminal has a first extending portion that is bent from the upper portion in the axial direction to the lower stage in the axial direction from the intersection to the tip, and has a second extending portion. The coil terminal includes a second extending portion that is bent and extends from the lower portion in the axial direction to the upper stage in the axial direction from the intersection to the tip.

Therefore, even when the first coil terminal and the second coil terminal are urged in a direction away from each other by the springback generated in the coil, the first and second extending portions arranged so as to intersect with each other are brought into contact with each other. As a result, the springback force is urged in the contact direction, so that the expansion of the coil outward in the radial direction can be suitably regulated. As a result, compared to the conventional reactor that had to be assembled while suppressing the springback of the coil, the coil can be easily and surely assembled to the core, so that the assembly workability can be improved. ..

It is external perspective view of the reactor which concerns on embodiment of this invention. It is the whole plan view of the reactor shown in FIG. 3A is an enlarged side view of the vicinity of the first and second ends in the reactor of FIG. 1, and FIG. 3B is an enlarged front view showing the vicinity of the first and second ends of FIG. 3A. It is the whole plan view of the reactor which concerns on a modification.

Suitable embodiments of the reactor according to the present invention will be given and will be described in detail below with reference to the accompanying drawings. In FIG. 1, reference numeral 10 indicates a reactor according to an embodiment of the present invention.

As shown in FIGS. 1 and 2, the reactor 10 includes a coil 12 whose both ends are pulled out from the outer peripheral side and wound by α winding, and a bobbin 14 in which the coil 12 is wound on the outer peripheral side. The coil 12 and the core 16 in which the bobbin 14 is housed are included.

For the coil 12, for example, a flat conducting wire covered with an insulating film such as enamel and having conductivity is used, and the outer peripheral side of the bobbin 14 is wound α in two layers in the vertical direction so that the wide surface thereof is in the radial direction. It is wound around. The bobbin 14 is formed in a cylindrical shape from, for example, a resin material, and a shaft portion 30 of a core 16 described later is inserted therein.

Specifically, the coil 12 is formed with an upper layer (first winding layer) 22 and a lower layer (second winding layer) 24, which are wound a plurality of times, respectively, and the first end portion 18 and the lower layer, which are the ends of the upper layer 22, are formed. The second end 20, which is the end of 24, is pulled out outward. A portion connecting the upper layer 22 and the lower layer 24 is provided in the middle of the coil 12. The upper layer 22 and the lower layer 24 of the coil 12 are formed with the same number of turns, and the outermost peripheral diameters thereof are formed to be substantially the same.

As described above, in the coil 12, the first end portion 18 which is one end along the winding direction is radially outward from the outermost outer peripheral portion 22a which is the outermost peripheral side in the winding portion of the upper layer 22 of the two layers. The second end portion 20, which is the other end, is drawn out radially outward from the outermost outer peripheral portion 24a, which is the outermost peripheral side in the winding portion of the lower layer 24 of the two layers.

Further, the first and second end portions 18 and 20 extend so as to intersect each other when viewed from the axial direction of the coil 12 (in the directions of arrows A1 and A2 in FIG. 1) as shown in FIG. The intersecting portion becomes the intersecting portion 26, and the first end portion 18 is located on the upper side in the axial direction when viewed from a direction orthogonal to the extending direction of the first and second end portions 18 and 20 shown in FIG. 3A. The upper layer 22 is bent downward (lower layer 24 side, arrow A2 direction), and the second end portion 20 is folded upward (upper layer 22 side, arrow A1 direction) from the lower layer 24 which is axially lower. Be tuned.

As a result, the bent portion of the first end portion 18 and the bent portion of the second end portion 20 intersect in a substantially X-shaped cross section, and a contact portion 28 in which the side surfaces facing each other are in contact with each other is formed ( (See FIG. 2). That is, the first end portion 18 and the second end portion 20 are formed so as to intersect in the vertical direction (arrows A1 and A2 directions) as well.

The first and second end portions 18 and 20 are bent outward in the radial direction of the coil 12 at the tip end side of the contact portion 28, and the first and second end portions 18a, respectively, extend in a straight line. It has 20a, and as shown in FIG. 3B, the tips of the respective tips are offset in the vertical direction (arrows A1 and A2) and are arranged in parallel in the thickness direction (arrow B direction). ..

As shown in FIGS. 1 and 2, for example, the core 16 is formed from a magnetic material in a substantially circular cross section, and a columnar shaft portion 30 projecting upward (in the direction of arrow A1) is located at the center thereof. A storage space 32 is formed, and the bobbin 14 around which the coil 12 is wound is inserted and stored on the outer peripheral side of the shaft portion 30.

Further, the core 16 has a drawer groove (opening) 34 extending outward from the storage space 32 formed on the outer peripheral side of the shaft portion 30, and the drawer groove 34 has the coil 12 of the coil 12. The first and second end portions 18 and 20 are inserted and pulled out to the outside. The intersection 26 and the contact portion 28 of the coil 12 are provided at positions outside the lead-out groove 34.

As described above, in the present embodiment, the coil 12 wound around the bobbin 14 by α winding so as to form two stages of the upper layer 22 and the lower layer 24, and the core 16 in which the coil 12 is housed are provided. The first end portion 18 and the second end portion 20 of the coil 12 extend radially outward from the outermost outer peripheral portions 22a and 24a of the upper layer 22 and the lower layer 24, respectively, and are viewed from the axial direction of the coil 12. At the same time as intersecting, the first end portion 18 is bent downward from the upper axial stage to extend, and the second end portion 20 is bent upward from the lower stage in the axial direction to extend.

Therefore, the first and second end portions 18, 20 taken out from the upper layer 22 and the lower layer 24 in the radial direction are crossed when viewed from the axial direction of the coil 12, and then folded so as to intersect in the vertical direction as well. By bending and extending, the springback acting on the coil 12 is urged in the direction of approaching each other, and the first and second end portions 18 and 20 move in the direction of approaching each other (inward) and come into contact with each other. The portions 28 can be brought into contact with each other.

As a result, even when the wound coil 12 tries to expand radially outward by springback, the first end portion 18 and the second end portion 20 are maintained in contact with each other at the contact portion 28. Therefore, the spread of the coil 12 can be suitably regulated.

As a result, when assembling the coil 12 to the core 16, the wound state of the coil 12 is maintained under the contact action of the contact portion 28, so that the operator needs to assemble while suppressing the springback of the coil 12. Compared with the conventional reactor, the coil 12 can be assembled easily and surely, the assembling workability can be improved, and the first and second end portions 18 and 20 are specified from the core 16. It can be taken out at the position of.

Further, since the expansion of the coil 12 can be suppressed without using other members, the number of parts and the manufacturing cost can be reduced as compared with the case where a member for suppressing the springback is separately provided, for example. Is possible.

Further, the reactor 10 described above has a configuration in which the first end portion 18 and the second end portion 20 covered with the insulating coating are brought into direct contact with each other via the contact portion 28 outside the core 16, for example. As in the reactor 50 shown in FIG. 4, direct contact is avoided by providing an insulating member 52 made of a resin material, ceramic, or the like between the first end portion 18 and the second end portion 20 of the coil 12. You may try to do so.

In the reactor 50, the first end portion 18 and the second end portion 20 are urged in a direction of approaching each other by a springback, so that the insulating member 52 is preferably sandwiched between them. The surfaces of the first and second ends 18 and 20 are coated with an insulating film to maintain the insulating property, but an insulating member 52 is provided between the two to prevent physical contact. By doing so, a higher insulation effect can be obtained.

It should be noted that the reactor according to the present invention is not limited to the above-described embodiment, and of course, various configurations can be adopted without departing from the gist of the present invention. Further, in the above description, the first and second end portions 18 and 20 are bent outward in the radial direction of the coil 12 on the tip side of the contact portion 28, but the bending angle is arbitrary, for example. It is also possible to set the angle of.

10, 50 ... Reactor 12 ... Coil 14 ... Bobbin 16 ... Core 18 ... First end 20 ... Second end 22 ... Upper layer 24 ... Lower layer 26 ... Intersection 28 ... Contact 34 ... Drawer groove 52 ... Insulation member

Claims (3)

A coil having first and second winding layers having two stages in the axial direction, the first and second winding layers being wound around a bobbin by α winding, and a core accommodating the coil together with the bobbin. In a reactor in which the first winding layer is arranged in the upper axial direction and the second winding layer is arranged in the lower axial direction.
A first coil terminal extending radially outward from the outermost peripheral portion of the first winding layer and being drawn out from the opening of the core.
A second coil terminal extending radially outward from the outermost peripheral portion of the second winding layer and being drawn out from the opening of the core.
An intersection between the tip of the first coil terminal and the second coil terminal and the outermost peripheral portion so as to partially overlap in the axial direction of the coil.
With
The first coil terminal includes a first extending portion that is bent and extends from an axially upper stage to an axially lower stage from the intersection to the tip, and the second coil terminal is from the intersection to the tip. A reactor comprising a second extending portion that is bent and extends from the lower axial stage toward the upper axial direction. In the reactor according to claim 1,
The first and second extending portions are reactors provided so as to be in contact with each other in a direction substantially orthogonal to the extending direction thereof. In the reactor according to claim 1,
A reactor comprising an insulating member between the first extending portion and the second extending portion.

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