JP2845075B2 - Coil parts - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil component such as a transformer and a choke coil used in various electronic devices.

[0002]

2. Description of the Related Art In recent years, coil components such as transformers and choke coils used in various electronic devices have been improved in electrical characteristics such as low loss, low heat generation, high efficiency, and low leakage flux, as well as small and light. Is being requested.

Hereinafter, a transformer will be described as an example of a conventional coil component with reference to FIGS. 7 and 8, an E-shaped laminate in which at least a primary winding and a secondary winding 3 are wound around a coil bobbin 2 having flanges 1 at both ends and laminated to a predetermined thickness on the coil bobbin 2 The iron core 4 is inserted, and an I-shaped laminated core 5 laminated to a predetermined thickness is butted on the magnetic leg end side of the E-shaped laminated core 4,
The butted portions are connected by welding or fixed using a metal frame or the like.

[0004]

In the above-mentioned conventional configuration,
As shown in FIGS. 9A and 9B, the E-shaped laminated core 4
The clearance A between the outer periphery of the winding 3 and the coil bobbin 2 and both outer magnetic legs of the E-shaped laminated core 4, the center hole of the coil bobbin 2 and the central magnet of the E-shaped laminated core 4 It provided in advance the clearance a between the legs, and because the required clearance B from deformation of the coil bobbin 2 by winding tension, miniaturization of the transformer winding space is reduced, the thinner large fault Had become.

Further, by providing the clearances A and B, since an air layer exists between the winding 3 or the coil bobbin 2 and the E-shaped laminated iron core 4, the heat radiation is deteriorated, the temperature rises sharply, and vibration occurs. It was also inferior in reliability, such as ease of use.

Further, an E-shaped laminated iron core 4 is used as the iron core.
And the I-shaped laminated iron core 5, the butted portions of the two iron cores 4 and 5 are orthogonal to the flow of magnetic flux,
This butted portion is to serve as a magnetic gap, leakage lot of Ri low leakage flux of the magnetic flux in the butted portion had become difficult.

Further, since the clearance is increased as described above, in order to make the most effective use of the winding space, it is necessary to arrange the winding 3 as an aligned winding. An expensive winding device is required as the winding device.

Further, when the insertion angle of the E-shaped laminated core 4 with respect to the coil bobbin 2 is shifted as shown in FIG. 10 or when the outer diameter of the winding 3 is too large as shown in FIG. The outer surface of the winding 3 was damaged at the corners of the magnetic legs of the E-shaped laminated iron core 4 when inserting the same, causing poor insulation and resulting in poor safety.

For this reason, as shown in FIG. 12, the outer diameter of the winding 3 is often increased, so that after the winding of the winding 3, the outer shape of the winding 3 is adjusted. Pressing from both sides of the winding 3 using a jig 6 is also practiced, but this winding shaping process induces cracking and deformation of the coil bobbin 2, and further causes disconnection of the winding 3 and insulation of the winding 3. to cause secondary defects such as deterioration, it has been a major problem in terms of reliability.

SUMMARY OF THE INVENTION It is an object of the present invention to eliminate the above-mentioned conventional disadvantages and to provide a coil component which can be made light and thin and which has excellent electrical characteristics.

[0011]

In order to solve the above-mentioned problems, a coil component according to the present invention has a triangular portion having tapered surfaces on both sides at both ends as a center magnetic leg incorporated in the center of the winding. A pair of C-shaped laminated cores having a tapered surface that matches one of the triangular portions of the I-shaped laminated core at both ends as magnetic legs on both sides using an I-shaped laminated core. The core is pressed against the I-shaped laminated core with the outer surface of the winding pressed against the inner surface of the C-shaped laminated core to eliminate the gap in the winding.
And has a configuration was.

[0012]

With the above construction, the clearance between the winding and the iron core can be minimized, the air space can be reduced, and the air gap in the winding can be eliminated, and the heat radiation can be improved.
As a result , the electrical characteristics can be improved.

[0013]

FIG. 1 shows an embodiment of a coil component according to the present invention.
This will be described with reference to FIG.

First, a transformer will be described as a typical example of a coil component with reference to FIGS. 7 is a coil bobbin having a flange 8 at both ends, at least one winding in this coil bobbin 7, windings 9 of the secondary winding are wound. The winding start, the intermediate tap, and the winding end of the winding 9 are connected to terminals 10 provided on the flange 8 of the coil bobbin 7.

In the center hole 11 of the coil bobbin 7, an I-shaped laminated core 12 laminated to a predetermined thickness is incorporated as a center magnetic leg. This I-shaped laminated iron core 12
At both ends, a triangular portion 14 having a 45-degree tapered surface 13 on both sides is formed.

A C-shaped laminated core 15 laminated to a predetermined thickness from both sides of the coil bobbin 7 is incorporated as a side magnetic leg. The C-shaped laminated core 15 has a tapered surface 16 at both ends that matches the tapered surface 13 of the triangular portion 14 of the I-shaped laminated core 12. 12 are assembled from both sides to form a closed magnetic circuit iron core in the shape of a letter.

Further, when assembling the C-shaped laminated core 15 from both sides of the coil bobbin 7, an insulating sheet 17 is disposed on the inner side of the C-shaped laminated core 15, and the C-shaped laminated core 15 and the winding 9 are connected to each other. Make insulation more reliable.

The C-shaped laminated iron core 15 is
In assembling the I-shaped laminated iron core 12 from both sides of the coil bobbin 7, the outer peripheral surface of the winding 9 wound around the coil bobbin 7 is pressed so that the tapered surfaces 16 at both ends become I-shaped.
Tapered surface 13 of triangular portion 14 of shaped laminated iron core 12
The C-shaped laminated iron cores 15 on both sides are pressed against the I-shaped laminated iron core 12 and welded to each other,
The assembled transformer is completed using the coupling hardware.

With this configuration, the clearance between the winding 9 and the iron core will be described with reference to FIGS. 3A and 3B. The size of the center hole 11 of the coil bobbin 7 is different from that of the I-shaped laminated iron core 12. The clearance C is set to the minimum dimension, and the height h of the flange 8 of the coil bobbin 7 is set to the tapered surface 16 of the C-shaped laminated core 15 and the I-shaped laminated core 1.
The size is set to be equal to the size of the window hole of the closed magnetic path iron core formed when the two tapered surfaces 13 match.

Therefore, the winding 9 may be wound by a non-aligned winding, and the height h of the flange 8 of the coil bobbin 7
The outer diameter of the coil bobbin 7 on the inner surface that contacts the winding 9 of the C-shaped laminated core 15
The coil 9 is mounted so as to press the outer peripheral surface of the wound coil 9 wound higher and to adjust it, while forcing the deformation of the coil bobbin 7 due to the winding tension and to match the I-shaped laminated iron core 12.

With the above configuration, even if there is a gap between the winding layers as the winding 9, this gap can be eliminated by the pressing force of the C-shaped laminated iron core 15, and as a result, the coil bobbin 7 I-shaped laminated iron core 1
A transformer having an air gap with only the clearance C of 2, the Joule heat generated in the winding 9 is also efficiently radiated to the outside through the iron core.

For this heat radiation, the outer circumference of the I-shaped laminated iron core 12 is coated with a synthetic resin by an application method or the like to form an insulating layer, and if the coil bobbin 7 is used instead, the clearance C is further reduced. And the effect can be further obtained. In the above embodiment, the insulating sheet 17 is connected to the inner surface of the C-shaped laminated core 15 and the winding 9.
However, if there is no burr or the like on the inner surface of the C-shaped laminated iron core 15, the heat dissipation can be further enhanced by omitting the insulating sheet 17.

As the insulating sheet 17, FIG.
(A) to (d), bent pieces 18 are provided on four sides of a U-shape and a rectangular body, two opposing ones are set to one, and the remaining two are bent in opposite directions. A mere sheet or a thick shape can be used, and as the material thereof, a material having excellent heat conductivity and insulation such as paper, nonwoven fabric, and polyester film can be used. Of these, as shown in FIG. 5, when a sponge-like insulating sheet 17 such as a non-woven fabric is used, the winding 9 is made more elastic when the C-shaped laminated iron core 15 is incorporated as compared with a case made of a polyester film or paper. By pressing, as shown in FIG. 6, the adhesion between the insulating sheet 17 and the windings 9 is improved to enhance the heat dissipation, and the stress on the windings 9 can be minimized.

Further, the effect can be obtained by applying and coating an insulating material on the inner surface of the C-shaped laminated iron core 15 instead of the insulating sheet 17.

The I-shaped laminated iron core 12 and the C-shaped laminated iron core 15 have tapered surfaces 13 and 16 whose abutment surfaces are 45 degrees with respect to the direction of the magnetic flux, so that a magnetic gap is formed here. Due to the part of the C-shaped laminated iron core 15 that bends the magnetic flux to the outer magnetic legs at right angles, the area of the butted portion is about 1.4 times the area of the conventional butted portion. By increasing the area, the leakage flux can be significantly reduced. In the above embodiment, the tapered surfaces 13 and 16 are used.
Is shown as having an angle of 45 degrees, but this need not necessarily be 45 degrees and can be various angles.

Furthermore, the I-shaped laminated iron core 12 and the C-shaped laminated iron core 15 having a block structure are advantageous in assembling and the like.

In the above embodiment, the transformer is used as an example. However, a similar configuration can be applied to a choke coil and the like, and the same effect can be obtained.

[0028]

As described above, since the coil component of the present invention is configured, the clearance between the winding itself, the winding or the coil bobbin and the iron core can be reduced, so that an air layer is formed between them. This minimizes the space factor of the winding and significantly improves the heat dissipation.

In particular, since the outer peripheral portion of the winding is pressed by the C-shaped laminated iron core, an air layer in the winding can be further reduced, and the generation of vibration such as a beat can be suppressed to a minimum. In addition, since the I-shaped laminated core and the C-shaped laminated core are butted by using a tapered surface, the generation of leakage flux can be significantly reduced, and a sufficient effect can be exerted even on the recent high-density mounting of electronic devices. Become.

Further, it has many advantages such that the winding is not damaged at the time of assembling and the insulating property is not deteriorated and the reliability is high, and the industrial value is great. .

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing one embodiment of a coil component of the present invention.

FIG. 2 is a perspective view of the coil component.

FIG. 3 (a) is a plan view showing a cross-section of a part of an assembled state of the coil component, and FIG.

4A to 4D are perspective views of an insulating sheet used for the coil component.

FIG. 5 is a plan view showing a part of the assembled coil component in a sectional view;

FIG. 6 is an enlarged explanatory view of the main part.

FIG. 7 is a perspective view showing a conventional coil component.

FIG. 8 is an exploded perspective view of the same.

9A is an explanatory view showing a clearance between a winding part of the coil component and an iron core. FIG. 9B is an explanatory view showing a deformation of the coil bobbin.

FIG. 10 is an explanatory view showing an inconvenient state when assembling the coil component.

FIG. 11 is an explanatory view showing an inconvenient state when assembling the coil component.

FIG. 12 is a perspective view showing a step of shaping the winding.

[Explanation of symbols]

 7 Coil bobbin 8 Flange 9 Winding 10 Terminal 11 Center hole 12 I-shaped laminated iron core 13 Tapered surface 14 Triangular portion 15 C-shaped laminated iron core 16 Tapered surface 17 Insulation sheet

────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Kazusa Mori 1006 Kazuma Kadoma, Osaka Prefecture Inside Matsushita Electric Industrial Co., Ltd. −5614 (JP, U) Actual opening 52-134713 (JP, U) (58) Fields investigated (Int. Cl. ⁶ , DB name) H01F 27/24-27/32

Claims (3)

(57) [Claims] 1. A triangular portion having tapered surfaces on both sides at both ends as a center magnetic leg incorporated in the center of a winding.
A pair of C-shaped laminated cores having a tapered surface that matches one tapered surface of the triangular portion of the I-shaped laminated core at both ends as both-side magnetic legs using a pair of C-shaped laminated cores. the coil component bound to eliminate voids in the pressed winding inside surface of the C-shaped laminated iron cores the outer surface of the winding relative to the I-shaped laminate core. 2. A claim made with by winding the winding coil bobbin having a flange at least on both ends as the winding
2. The coil component according to 1 . 3. A coil component of the serial <br/> mounting in claim 1 ing with intervening insulating sheet between the outer surface of the inner surface and the windings of the C-shaped laminated core.