JP3346188B2 - choke coil - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a choke coil used for consumer or industrial electronic equipment.

[0002]

2. Description of the Related Art A conventional thin choke coil will be described with reference to FIGS. 42 is an exploded perspective view, FIG. 43 is a perspective view showing a state in which a coil is incorporated in a closed magnetic circuit core, FIG. 44 is a perspective view of a completed product, FIG. 45 is a sectional view, and FIG. 46 is a state in which one of the magnetic cores is removed. It is a top view. In FIG.
Is a rectangular insulated conducting wire, 2 is an air-core coil, 3 is an inner peripheral portion of the air-core coil 2, 4 is a coil outer peripheral portion, 5 is an inner peripheral terminal, 6 is an outer peripheral terminal, 7 is a center magnetic leg, and 8 is an outer leg. A magnetic leg, 9 is a common magnetic leg, 10 is a closed magnetic circuit core, and 12 is a window height of the closed magnetic circuit core 10. The flat rectangular insulated conducting wire 1 is spirally wound to form an air-core coil 2; Inner peripheral terminal 5 on peripheral part 3
Further, the outer peripheral portion 4 is connected to the outer peripheral terminal 6 by soldering or the like, and the air core coil 2 and the insulating paper 11 are mounted on the center magnetic leg 7 of the closed magnetic circuit core 10.

[0003]

However, in the above-mentioned conventional configuration, the terminal 5 of the inner peripheral portion is connected to the inner peripheral portion 3 of the air-core coil 2, and the common magnetic leg 9 of the air-core coil 2 and the closed magnetic path core 10 is connected. Since it is drawn out from between, the thickness of the terminal 5 on the inner peripheral portion is added to the window height 12 of the closed magnetic circuit core 10, and a dead space is generated in the direction of the window height 12 so that the space factor is reduced, and the thickness of the choke coil is reduced. There was a problem of difficulty.

Further, since the terminal 5 on the inner peripheral portion is drawn out from between the air core coil 2 and the common magnetic leg 9 of the closed magnetic circuit core 10, the terminal cannot have a large sectional area, and is thin and can handle a large current. There was a problem that choke coils could not be formed.

An object of the present invention is to reduce the height of a choke coil and reduce the thickness and increase the current.

[0006]

SUMMARY OF THE INVENTION In order to solve this problem, a choke coil according to the present invention includes a closed magnetic circuit core having a central magnetic leg, an outer magnetic leg, and a common magnetic leg, and the central magnetic leg of the closed magnetic circuit core. An air-core coil in which a plate-shaped wire made of a flat wire or a foil-shaped copper wire is spirally wound is attached to at least the inner peripheral portion of the air-core coil among the terminals connected to both ends of the plate-shaped wire of the air-core coil. Through the notch provided in at least one of the common magnetic legs of the closed magnetic circuit core.
This notch has an inner periphery of the air-core coil.
Insulator layer between the core and the center leg of the closed magnetic circuit core
And an insulator layer that fits into the notch
The insulating layer that fits in between the bottom surface of the air-core coil and the air-core coil
This is a structure interposed between the terminal and the terminal drawn out from the inner peripheral portion .

[0007] With this configuration, among the closed magnetic path core because it pulled out to the outside through a notch provided with a drawer inner periphery terminals provided on the inner periphery of the air-core coil on one common magnetic leg of the closed magnetic circuit core The thickness of the peripheral terminal does not affect the window height of the closed magnetic circuit core, so there is no dead space in the window height direction, the space factor can be improved, the window height of the closed magnetic circuit core can be reduced, and a choke coil with a lower height can be used. Can be realized, and the thickness of the inner peripheral terminal can be increased and the cross-sectional area can be increased, so that it is possible to cope with a large current.

Further, the positions of the air-core coil and the closed magnetic core are determined.
Can be determined, and characteristic variations can be reduced.
The air-core coil can be separated from the closed magnetic core by the insulator layer.
Small number of parts, characteristic stability, workability and reliability
An excellent choke coil can be supplied.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention according to claim 1 of the present invention comprises a closed magnetic core having a central magnetic leg, an outer magnetic leg and a common magnetic leg, and the central magnetic leg of the closed magnetic core has a rectangular conductor or An air-core coil in which a plate-shaped conductor made of a foil-shaped copper wire is spirally wound is attached, and among the terminals connected to both ends of the plate-shaped wire of the air-core coil, terminals provided at least on the inner peripheral portion of the air-core coil are provided. It is drawn out through a notch provided in at least one of the common magnetic legs of the closed magnetic circuit core.
In the notch, the inner circumference of the air core coil and the central magnetic leg of the closed magnetic core
Between the insulator layer and the notch
The insulator layer is provided integrally, and the insulating layer that fits
End drawn from the lower surface of the coil and the inner periphery of the air-core coil
It is interposed between the child.

As a result, dead space in the window height direction of the closed magnetic circuit core can be eliminated, the space factor can be improved, the window height of the closed magnetic circuit core can be reduced, and the thickness of the inner peripheral terminal can be increased to increase the sectional area. Therefore, it is possible to cope with a large current, and it is possible to supply a choke coil corresponding to a large current having a lower height.

Further, the positions of the air core coil and the closed magnetic circuit core are
Can be determined, and characteristic variations can be reduced.
The air-core coil can be separated from the closed magnetic core by the insulator layer.
Small number of parts, characteristic stability, workability and reliability
An excellent choke coil can be supplied.

According to a second aspect of the present invention, the closed magnetic path magnetic core is a combination of the EE type, the EI type or the TU type. Can be wider.

[0013] The invention according to claim 3, which has provided a magnetic gap in the center magnetic leg in addition to the first aspect as a closed magnetic path core, without increasing the leakage magnetic flux to the closed magnetic circuit core outside The current superposition characteristics of the choke coil can be improved, and a choke coil having a low leakage magnetic flux and a large current capacity can be supplied.

According to a fourth aspect of the present invention, in addition to the configuration of the first aspect, the cross section of the center magnetic leg of the closed magnetic circuit core is circular, oval, or elliptical. On the other hand, the window width of the magnetic core of the closed magnetic circuit can be made larger, and the size of the choke coil can be reduced.

According to a fifth aspect of the present invention, in addition to the configuration of the first aspect, a portion of the common magnetic leg of the closed magnetic circuit core corresponding to the terminal inside the common magnetic leg on the side where the notch is not provided is provided. It has a recess, notch, or hole.Even if the tip of the terminal connected to the plate-shaped conductor of the air-core coil protrudes from the end face of the air-core coil, there is no contact between the terminal and the magnetic core of the closed magnetic path, and the closed magnetic path is closed. It is possible to eliminate defective assembly of the magnetic legs,
It is possible to supply a choke coil with high workability and high reliability.

[0016] The invention according to claim 6, using a magnetic core of EI-shaped as closed magnetic path core in addition to the first aspect, configuration and a notch to draw inner terminal of the air-core coil provided on the I-shaped core The position of the I-shaped core and the E-shaped core with respect to the air-core coil can be determined, and the center magnetic leg of the E-shaped core can prevent displacement of the insulating sheet. An excellent choke coil can be supplied.

According to a seventh aspect of the present invention, in addition to the configuration of the first aspect, the thickness of the common magnetic leg on the side of the common magnetic leg on which the notch for leading out the terminal is provided is 1 as the closed magnetic circuit core. When the notch is not provided, the thickness of the common magnetic leg
It is those where the structure was 0.9, the notch of the common core
It is possible to prevent deterioration of the bias characteristics of the closed magnetic circuit core due to, excellent current superimposition characteristic can supply thin choke coil.

According to an eighth aspect of the present invention, in addition to the structure of the first aspect, a self-fusing flat insulated wire is used as the air core coil, so that an air core coil having high dimensional accuracy can be formed, and workability can be improved. Improvements and automation are possible.

According to a ninth aspect of the present invention, in addition to the configuration of the first aspect, the air-core coil has a circular shape, an elliptical shape, or an elliptical shape corresponding to the shape of the center magnetic leg of the closed magnetic core. A choke coil with excellent efficiency and winding workability can be supplied.

According to a tenth aspect of the present invention, in addition to the configuration of the first aspect, both ends of the plate-shaped conductor constituting the air-core coil are bent so as to project inward and outward. Breakdown of interlayer insulation due to edges at both ends of the plate-shaped conductor can be prevented, and a highly reliable choke coil can be supplied.

According to an eleventh aspect of the present invention, in addition to the configuration of the first aspect, a spacer is interposed between a connection portion of a terminal connected to both ends of the air-core coil and a plate-shaped conductor of the air-core coil. In addition, destruction of interlayer insulation due to burrs at terminal connection portions can be prevented, and a highly reliable choke coil can be supplied.

According to a twelfth aspect of the present invention, in addition to the configuration of the eighth aspect, the distance from the portion where the terminal is connected to the end as the air-core coil is slightly increased, and the self-fusing rectangular insulating material is used. It is possible to supply a choke coil that is excellent in workability and can be automated, because it secures and secures both ends at the extended portion from the part where the terminal of the wire is connected to the end, preventing winding collapse of the air core coil. Becomes

The invention according to claim 13 is the same as the structure of claim 1.
In addition to the inner core of the air core coil and the central magnetic leg of the closed magnetic core
Fits the insulator layer interposed between the center magnetic legs
Cylindrical shape, inside air core coil and closed magnetic core
Clearance with the center leg can be reduced, space factor, reliability
It is possible to supply an excellent choke coil.

According to a fourteenth aspect of the present invention, the structure of the first aspect is provided.
In addition to the inner core of the air core coil and the central magnetic leg of the closed magnetic core
And the insulator layer interposed between the
The insulating layer that fits into the notch
The terminals that hold the terminals at both ends of the air-core coil
The terminal is connected to the closed magnetic circuit core.
Choke with excellent terminal accuracy
Can supply coils.

The invention according to claim 15 is the invention according to claim 14.
In addition to the configuration, the outer periphery of the terminal block must be
A wall piece that holds the outer peripheral surface of the air core coil with the edge layer
Dimensions of air-core coil and terminal block
Position change with respect to
We can supply choke coils with excellent workability and reliability.

The invention according to claim 16 is the invention according to claim 15.
In addition to the configuration, the tape
The air core coil is a wall piece.
Guide with a taper to facilitate insertion into the terminal block
You.

According to a seventeenth aspect of the present invention ,
In addition to the configuration, insert molding two terminals on the terminal block,
Both terminals are pulled out from the same direction.
Yes, air core coil can be positioned accurately, air core coil
Automation of insertion and terminal connection becomes possible.

The invention according to claim 18 is the invention according to claim 15
In addition to the configuration, the insulator layer on the inner periphery of the air core coil of the terminal block
The bent portions at both ends of the air-core coil are engaged with the wall piece.
Of the air core coil due to the engagement of the inner circumference of the air core coil.
Air core coil built into the terminal block by engaging the outer periphery
Preventing winding collapse of Le, characteristic stability, workability, reliability
Enables supply of excellent choke coils.

The invention according to claim 19 is the invention according to claim 14.
Terminal connected to both ends of air core coil on terminal block in addition to the configuration
The guide part of
Terminal position on the inner periphery of the
Choke coil that can be automated and has excellent workability and reliability
Can be supplied.

The invention according to claim 20 is the invention according to claim 14
In addition to the configuration, an outer frame is
Incorporating a magnetic core with outer magnetic legs from below the outer frame
The air-core coil is a magnetic core using the outer frame as a guide.
It can be integrated into the system and can be automated and has excellent workability
The choke coil can be supplied.

The invention according to claim 21 is the invention according to claim 20.
In addition to the configuration, a part of the outer frame is connected to the outer periphery of the air core coil.
A guide section is provided to guide the terminals
The air-core coil.
The terminal can be pulled out from both directions and held on the terminal block.
Chocolate with low number of parts, excellent terminal accuracy and workability
Supply of ills.

[0032] The invention according to claim 22 is the invention according to claim 20.
In addition to the configuration, assembled from above inside the four corners of the outer frame
And a holding portion for holding the magnetic core.
And the positioning of the magnetic core installed from above
Choke coil with excellent workability and characteristic stability
Can be supplied.

[0033] The invention according to claim 23 is the invention according to claim 20.
In addition to the configuration, when the outer frame incorporates a closed magnetic core,
It is designed to have a height that covers the outer surface of the leg side,
The outer surface of the magnetic core can be insulated.
Insulation with other parts is possible.

[0034] The invention according to claim 24 is the structure according to claim 1.
It has a circular center magnetic leg as a closed magnetic path core in addition to
So, as an air core coil to be incorporated into this closed magnetic circuit core,
The shape of the inner peripheral part is the center facing the connection part between the winding start part and the terminal.
Only the distance from the side of the magnetic leg is about twice or more the thickness of the plate-shaped conductor.
The other part is an elliptical shape that becomes a circle similar to the central magnetic leg
The air core coil and the center magnetic leg
There is no wasted space between the terminal connection at the beginning of the winding and the central magnet.
The required space can be obtained between the hearts, and the space factor is excellent.
Air-core coil with smaller size, smaller and smaller board mounting area
This enables a small choke coil.

According to a twenty-fifth aspect of the present invention, the structure of the first aspect is provided.
In addition to the core, air-core coils are attached to the inner surfaces of both outer magnetic legs of the closed magnetic core.
With a concave notch to fit the outer circumference of
And the window width of the closed magnetic core can be increased.
Higher performance chows that can use large air core coils
It is possible to supply the coil.

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.

(Embodiment 1) A first embodiment of the present invention will be described with reference to FIGS. 1 to 5, reference numeral 20 denotes an air-core coil. The air-core coil 20 is formed by spirally winding a plate-shaped conductor 21 made of a rectangular conductor or a foil conductor. Specifically, the plate-shaped conductive wire 21 is wound in a spiral shape using a self-fusing flat rectangular insulated wire, heated to soften the self-fusing layer on the surface, and fused together to form the air-core coil 20. Is formed.

Plate-shaped terminals 22, 23 are connected to both ends of the air-core coil 20, that is, the inner and outer ends, and the terminals 22, 23 project below the air-core coil 20. Has been withdrawn. The terminals 22 and 23 are incorporated in a terminal block 24. That is, the terminal block 24
Is an arc-shaped piece 25 made of an insulating material such as a synthetic resin and rising upward along the inner peripheral surface of the air-core coil 20 at a position corresponding to the connection portion of the terminal 22 on the inner peripheral surface of the air-core coil 20; The arc-shaped piece 25 is formed by a triangular piece 26 connected at the lower end thereof, and the arc-shaped piece 25 and the triangular piece 26 each function as an insulator layer. this
At this time, the inner peripheral portion of the air core coil 20 and the center of the closed magnetic circuit core 32
An arc-shaped piece 25 of an insulator layer is interposed between the magnetic legs 34.
You.

The arc-shaped piece 25 of the terminal block 24 has a step portion 27 whose thickness is changed at an intermediate portion, and a triangular piece 26 corresponding to the step portion 27 has a terminal at the inner peripheral portion of the air-core coil 20. A terminal hole 28 through which the air-core coil 2 is inserted is provided.
A terminal hole 29 is provided in the triangular piece 26 corresponding to the terminal 23 on the outer periphery of the zero. Further, on the lower surface of the triangular piece 26, there are provided terminal grooves 30, 31 as terminal guide portions connected to the terminal holes 28, 29.
After the terminal block 24 is combined with the terminal block 24, the terminals 22 and 23 projecting from the lower surface of the terminal block 24 are bent and fitted into the terminal grooves 30 and 31, and are drawn laterally from the end face of the triangular piece 26 of the terminal block 24. ing.

The closed magnetic circuit core 32 is incorporated into the combination of the air-core coil 20 and the terminal block 24. The closed magnetic path magnetic core 32 is formed of an EE-shaped magnetic core 33 made of a ferrite sintered body, and includes a center magnetic leg 34, both outer magnetic legs 35, and a common magnetic leg 36. A notch 37 having a size to fit the shape piece 26 is provided.

With the above configuration, the terminal block 24 is attached to the air-core coil 20.
And the terminals 22, 23 are connected to the terminal grooves 30,
The E-shaped magnetic core 33 is assembled from above and below, and the triangular piece 26 of the terminal block 24 is fitted into the notch 37 of one of the E-shaped magnetic cores 33 and positioned.
By connecting the shaped magnetic cores 33, a choke coil having the terminals 22, 23 drawn out in the same direction as shown in FIG. 2 is formed. That is, under the air core coil 20
Between the surface and the terminal 22 pulled out from the inner peripheral portion of the air-core coil.
A triangular piece 2 of an insulator layer that fits into the cutout portion 37 between them
6 intervenes.

At this time, both outer magnetic legs 35 of the E-shaped magnetic core 33
If the height of the center magnetic leg 34 is made smaller than the height of the center magnetic leg 34, a choke coil having a magnetic gap 38 in the center magnetic leg 34 can be obtained, without increasing the leakage magnetic flux to the outside of the closed magnetic circuit core 32, The current superposition characteristics as a choke coil can be improved.

With the above-described configuration, the triangular pieces 26 and the terminals 22 and 23 of the terminal block 24 are arranged or pulled out by using the cutout portions 37 of the common magnetic leg 36 of the closed magnetic circuit core 32. Therefore, the common magnetic leg 3 of the closed magnetic circuit core 32
6, only the air core coil 20 can be interposed,
Since the dead space in the window height direction of the closed magnetic circuit core 32 is eliminated, the space factor can be improved, and the thickness of the terminals 22 and 23 can be increased and the cross-sectional area can be increased.

In the above embodiment, the closed magnetic circuit core 32
Although an EE type magnetic core 33 has been described as an example, an EI type magnetic core and a TU type magnetic core may be used. It may be in the form. This is air core coil 2
The air gap between the air core coil 20 and the center magnetic leg 34 may be reduced in accordance with the shape of the inner peripheral portion of the air core coil 20 after molding of 0 to improve the characteristics.

Embodiment 2 Next, a second embodiment of the present invention will be described with reference to FIGS. The basic configuration is the same as that of the first embodiment, and only different points will be described. That is, a different point lies in the configuration of the terminal block 24. A wall piece 39 rising upward is integrally provided on the outer end of the triangular piece 26, and a part of the inner and outer peripheral surfaces of the air-core coil 20 is partially Arc-shaped piece 25
And the wall piece 39.

The terminals 22 and 23 are insert-molded on the terminal block 24 in advance, and the ends of the inner and outer peripheral portions of the air-core coil 20 are inserted into the terminals 22 and 23.
23 is connected and fixed later by a method such as welding or soldering.

With such a configuration, it is possible to prevent a change in the outer dimensions of the air-core coil 20 and the position of the air-core coil 20 with respect to the terminal block 24, and to achieve excellent reliability with little variation in characteristics.

As an improvement of the second embodiment, FIG.
It can also be configured as shown in FIG. That is,
The shape of the inner peripheral portion of the air-core coil 20 is an ellipse or an ellipse to improve the space factor of the air-core coil 20 in the closed magnetic circuit core 32. That is, if the shape of the inner peripheral portion of the air-core coil 20 is made circular by the circular center magnetic leg 34 and the arc-shaped piece 25, a large amount of dead space is generated therebetween.

In order to make this dead space as small as possible, it is effective to make the shape of the inner peripheral portion of the air-core coil 20 into an elliptical shape or an elliptical shape. This is because the winding jig 40 shown in FIG.
A structure having an ellipse of 2t, which is about twice the thickness t of 1, is used to form and use a spiral air-core coil 20.

With this configuration, the air-core coil 20 having a small space factor and a high space factor can be provided, and a small-sized choke coil having a small mounting area can be provided.

Third Embodiment Next, a third embodiment of the present invention will be described with reference to FIGS.
9 will be described. In FIGS. 12 to 19, reference numeral 20 denotes an air-core coil, which has the same configuration as that of the first embodiment, and has terminals 22 and 23 connected to both ends thereof so as to protrude downward.

On the other hand, the terminal block 24 incorporated in the air-core coil 20 includes a cylindrical body 41 as an insulating layer between the air-core coil 20 and the center magnetic leg 34 of the closed magnetic circuit core 32, and a lower part of the cylindrical body 41. And a triangular piece 26 connected by a portion. The outer peripheral surface of the cylindrical body 41 is provided with a vertical groove 42 serving as a guide portion into which the terminal 22 connected to the inner peripheral portion of the air-core coil 20 is fitted. The triangular piece 26 at the lower end of the vertical groove 42 has a terminal. A hole 28 is provided.

Further, on the upper surface of the triangular piece 26, two wall pieces 39 are provided at a constant interval from the cylindrical body 41,
The surface of the wall piece 39 facing the cylindrical body 41 has a tapered portion 4.
3 are provided so that the air-core coil 20 can be incorporated while being guided by the tapered portion 43. Further, the triangular piece 26 is provided with a terminal hole 29 through which the terminal 23 connected to the outer peripheral portion of the air-core coil 20 is inserted, and a terminal guide connected to the two terminal holes 28, 29 is provided on the lower surface of the triangular piece 26. Terminal grooves 30 and 31 are provided as parts.

As the closed magnetic circuit core 32, EI type magnetic cores 44 and 45 are used.
It has both outer magnetic legs 35 and a common magnetic leg 36, and the common magnetic leg 36 is provided with a cutout 37 having a size to fit the triangular piece 26 of the terminal block 24. On the other hand, the I-shaped core 45 has a substantially rectangular plate shape, and a notch 46 is provided on a side corresponding to the notch 37 of the E-shaped core 44.
It has a configuration in which a concave portion 47 is provided inside. This notch 46 is for the terminal 23 connected to the outer peripheral portion of the air-core coil 20.
This is for escape when the upper part projects upward,
This is for escape when the terminal 22 connected to the inner peripheral portion of the air-core coil 20 projects upward and is connected.

As shown in FIG. 15, the I-shaped magnetic core 45 is not provided with the concave portion 47 and the terminal 22 is connected to the air-core coil 2.
If the terminal 22 protrudes above 0, the upper end of the terminal 22 contacts the lower surface of the I-shaped core 45 and cannot be combined with the E-shaped core 44. However, by providing the concave portion 47 as shown in FIG. E-shaped magnetic core 44
And the I-shaped magnetic core 45 can be combined exactly. The notch 46 of the I-shaped magnetic core 45 exhibits the same effect when the terminal 23 projects upward.

With such a configuration, the air core coil 20 to which the terminals 22 and 23 are connected is attached to the terminal block 24 shown in FIG.
9, the terminals 22, 23 are inserted into the terminal holes 28, 29, and the terminals 22, 23 projecting from the lower surface of the terminal block 24 are bent to form a triangular piece 2 of the terminal block 24.
6 are inserted into the terminal grooves 30 and 31 on the lower surface of the triangular piece 2.
6 is drawn out side by side, combined with an E-shaped core 44, and an I-shaped core 45 is disposed thereon and fixed, so that a magnetic gap is formed between the end face of the center magnetic leg 34 and the I-shaped core 45. The choke coil shown in FIGS.

Although the cylindrical body 41 and the triangular piece 26 are integrally molded with the resin as the terminal block 24, the terminal block 24 is formed as a separate body and is mechanically connected to the terminal block 24 by using an adhesive. It is good also as composition which is combined with.

Fourth Embodiment Next, a fourth embodiment of the present invention will be described with reference to FIGS.
This will be described with reference to FIG. 20 to 22, the configurations of the air-core coil 20 and the terminal block 24 are the same as those of the above-described third embodiment, and only the configuration of the closed magnetic circuit core 32 is changed. That is, the notch 37 is provided in the I-shaped core 45, the notch 46 is provided on one side of the E-shaped core 44, and the recess 47 is provided therein. According to this configuration, the air-core coil 20 is provided in the I-shaped core 45. The triangular pieces 26 of the terminal block 24 in which the terminals 22 and 23 are bent and combined are positioned and combined with the cutouts 37, and the E-shaped magnetic core 44 is connected to the terminal block 24.
The choke coil shown in FIGS. 21 and 22 can be constructed by fitting the central magnetic leg 34 into the cylindrical body 41 while positioning it.

With this configuration, the positioning of the I-shaped magnetic core 45 can be automatically performed by the terminal block 24, which is advantageous in terms of assemblability.

Fifth Embodiment Next, a fifth embodiment of the present invention will be described with reference to FIG. The basic configuration is the same as that of the fourth embodiment, except that the component constituting the closed magnetic core 32 is TU.
The point is that the cores 48 and 49 are used. That is, a T-shaped magnetic core 48 composed of the center magnetic leg 34 and the common magnetic leg 36 and a U-shaped magnetic core 49 composed of both outer magnetic legs 35 and the common magnetic leg 36 are used, and terminals are connected to the common magnetic leg 36 of the T-shaped magnetic core 48. A notch 37 is provided in which the triangular piece 26 of the base 24 is fitted, and a notch 46 and a concave portion 47 are provided on one side of the common magnetic leg 36 of the U-shaped magnetic core 49. Is obtained.

(Sixth Embodiment) Next, a sixth embodiment of the present invention will be described with reference to FIGS.
This will be described with reference to FIG. First, the air-core coil 20 will be described. The air-core coil 20 uses a plate-shaped conductive wire 21 made of a self-fusing rectangular insulated wire, but is wound in a spiral shape to maintain its shape by heating and self-fusing. However, there are cases where the end portions at the beginning and end of the winding are peeled off by the application of an external force and the spiral shape cannot be maintained.

Therefore, the connection between the terminals 22 and 23 is not provided as a start end or an end, but is provided with the extension portion 50 to extend the portion, thereby improving the self-fusing property when heated and preventing a spiral collapse. is there.

Moreover, the end portion is provided with a bent portion 51 which protrudes in the radial direction, that is, the inner peripheral portion is on the inner side, and the outer peripheral portion is on the outer side.

The terminal block 24 has a structure in which an outer frame 52 is provided integrally with the triangular piece 26, wall pieces 39 are provided near the four corners of the outer frame 52, respectively, and the outer magnetic legs 35 of the closed magnetic circuit core 32 are provided. The dimensions of the outer frame 52 corresponding to the height of the closed magnetic circuit core 32 are the same as the height of the closed magnetic circuit core 32 to protect the closed magnetic circuit core 32. Furthermore, the triangular piece 2 of the outer frame 52
The terminal 2 on the outer peripheral side of the air-core coil 20
3 is provided.

The cylindrical body 41 of the terminal block 24 has an uneven thickness structure in which a portion corresponding to the terminal 22 on the inner peripheral side of the air-core coil 20 is thickened.
2 is provided with a vertical groove 42 for guiding the same, and an engagement groove 53 for engaging the bent portion 51 at the end of the inner peripheral portion of the air-core coil 20 is provided at a slightly distant position. The triangular piece 26 corresponding to the lower end of the vertical groove 42 is provided with a terminal hole 28, and the lower surface of the triangular piece 26 is provided with a terminal groove 30 which is connected to the terminal hole 28.
The terminal groove 31 is also provided on the lower surface of the portion where the terminal hole 29 is provided.

That is, in the terminal block 24 having this configuration, the terminals 22 and 23 are drawn out in opposite directions, that is, in directions different from each other by 180 degrees, and are configured to be effective as a surface mounting choke coil. .

As the closed magnetic path magnetic core 32, an EI type magnetic core 44,
45, a concave notch 54 is provided in the center of the inside of the outer magnetic leg 35 of the E-shaped magnetic core 44 as a guide along the outer shape of the air core coil 20, so that the device can be made more compact. The I-shaped magnetic core 45 is provided with a concave portion 47 for escaping the terminal 22 on the inner peripheral side and a notch 46 on the side opposite to the cutout portion 37 of the E-shaped magnetic core 44 so as to escape the terminals 23 on the outer peripheral portion. .

On the lower surface of the I-shaped magnetic core 45, an insulating sheet 56 having a through hole 55 which fits with the center magnetic leg 34 at the center is incorporated to improve the insulation between the air core coil 20 and the I-shaped magnetic core 45. Is being planned.

The bent portion 51 at the end of the outer peripheral portion of the air-core coil 20 is one of the four wall pieces 39 provided integrally with the outer frame 52.
It is configured to be engaged with two end faces.

With such a configuration, the bent portion 51 of the air-core coil 20 is fitted to the engagement groove 53 and the wall piece on the terminal block 24 having the outer frame 52. The terminal hole 24 of the terminal block 24
The terminals 22 and 23 protruding from the lower surface through the holes 8 and 29 are bent and fitted into the terminal grooves 30 and 31, and an E-shaped magnetic core 44 having a columnar central magnetic leg 34 is assembled from the lower surface of the terminal block 24. Then, the state shown in FIG. 25 is obtained, and after the insulating sheet 56 is assembled, the I-shaped magnetic core 45 is assembled to form the choke coil shown in FIG.

The choke coil having this configuration protects the closed magnetic circuit core 32 from external impact to prevent breakage, and is excellent in safety. For example, the assembling property and the position fixing of the air core coil 20 can be reliably performed. It has many advantages.

As the air-core coil 20 in the above description, as shown in FIGS. 29 (a) and 29 (b), one end of a plate-shaped conductive wire 21 made of a self-fusing flat rectangular insulated wire is bent at a right angle. The two bent portions 51 are formed, and the terminals 22 and 23 are connected by caulking or welding to the portions where the conductor is exposed by removing the insulating layer at a portion slightly apart from both ends.
A spacer 57 as shown in FIG. 33 is attached to the opposite surface of the connection portions 2 and 23 due to burrs generated during connection, as shown in FIG. It fuse | fuses and bends so that the outermost end may protrude outside, and the bending part 51 is formed and it can be set as the structure as shown in FIG.

The bent portion 51 is provided at the end of the air-core coil 20.
In the case where is not required, a configuration as shown in FIG. 31 can be adopted.

Embodiment 7 Next, a seventh embodiment of the present invention will be described with reference to FIGS.
9 will be described. The seventh embodiment has the same basic configuration as that of the sixth embodiment, except for the terminal block 24 and the insulating sheet 56. That is, the terminal block 2
4 has an outer frame 52, a cylindrical body 41, and a triangular piece 26, but the outer magnetic legs 35 of the E-shaped core 44.
A support protrusion 58 also serving as a guide portion for the square air-core coil 20 of the outer frame 52 having a size that fits into the outer surface 52 is provided. A tapered notch 59 is provided in a part of the support protrusion 58, and an insulating sheet 56 is provided. At the four corners, engaging pieces 60 cut and raised downward are provided, and the engaging pieces 60 are fitted into the tapered notches 59 to position the insulating sheet 56.

A through hole 55 is not provided at the center of the insulating sheet 56, and the center magnetic leg 34 of the E-shaped magnetic core 44 and the I-shaped magnetic core 4
5 is formed by interposing the insulating sheet 56 therebetween.

With the above configuration, the air-cored coil 20 is incorporated into the terminal block 24 as shown in FIG. 35, the terminals 22, 23 are bent out in opposite directions and drawn out, and then as shown in FIG. The E-shaped magnetic core 44 is assembled from the lower surface of FIG.
As shown in FIG.
Of the I-shaped magnetic core 45 and the terminal block 24 and E.
As shown in FIG.
8, a choke coil shown in FIG.

As shown in FIG. 40, the center magnetic leg 34 of the E-shaped magnetic core 44 constituting the closed magnetic circuit core 32 has an elliptical or elliptical shape, and the air-core coil 20 has an elliptical or elliptical spiral shape as shown in FIG. As described above, the positioning may be performed in a shape by the combination of the two, and the space factor may be improved.

When the notched portion 37 is provided in one common magnetic leg 36 and the notched portion 37 is not provided in the other common magnetic leg 36 as the closed magnetic circuit core 32, the notched portion 37 is used.
When the thickness of the common magnetic leg 36 provided with
Even if the thickness of the common magnetic leg 36 having no 7 is reduced to 0.65 to 0.9, the characteristics of the choke coil remain unchanged, and the height of the choke coil can be reduced accordingly.

In each of the above embodiments, the notch 37 is formed in at least one of the common magnetic legs 36 of the closed magnetic circuit core 32.
However, instead of the notch 37, openings are provided in portions corresponding to the terminals 22 and 23 connected to the inner and outer peripheral portions of the air-core coil 20, and the terminal block 24 is replaced with the triangular piece 26. Alternatively, a plate piece shaped to fit into the opening may be used.

[0080]

As described above, since the choke coil of the present invention is constituted, substantially only the air-core coil can be arranged in the window between the common magnetic legs of the closed magnetic circuit core. In addition, there can be obtained an effect that a terminal having a large thickness can be used as a terminal for drawing out the air-core coil, and a large current can be handled.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a choke coil according to a first embodiment of the present invention.

FIG. 2 is a perspective view of a finished product of the choke coil.

FIG. 3 is a sectional view of the same.

FIG. 4 is a top view showing a state where the same magnetic core is removed;

FIG. 5 is a perspective view of a terminal block used in the choke coil.

FIG. 6 is a perspective view of a choke coil according to a second embodiment of the present invention.

FIG. 7 is a sectional view of the same.

FIG. 8 is a top view showing a state where the same magnetic core is removed.

FIG. 9 is a perspective view of a terminal block used for the choke coil.

FIG. 10 is a top view of the choke coil with one magnetic core removed;

FIG. 11 is an explanatory view of manufacturing the airless coil.

FIG. 12 is an exploded perspective view of a choke coil according to a third embodiment of the present invention.

FIG. 13 is a perspective view of the same.

FIG. 14 is a sectional view of the same.

FIG. 15 is a cross-sectional view showing an inconvenience when there is no concave portion of the I-shaped magnetic core in the same configuration.

FIG. 16 is a sectional view showing a state where a concave portion is provided in the I-shaped magnetic core;

FIG. 17 is a top view showing a state where the I-shaped magnetic core is removed;

FIG. 18 is a perspective view of the terminal block.

FIG. 19 is a perspective view showing a state where an air-core coil is combined with the terminal block.

FIG. 20 is an exploded perspective view of a choke coil according to a fourth embodiment of the present invention.

FIG. 21 is a perspective view of the completed product.

FIG. 22 is a sectional view of the same.

FIG. 23 is an exploded perspective view of a choke coil according to a fifth embodiment of the present invention.

FIG. 24 is an exploded perspective view of a choke coil according to a sixth embodiment of the present invention.

FIG. 25 is a perspective view showing a state where the airless coil and the terminal block are combined.

FIG. 26 is a perspective view of a state where the airless coil, the terminal block, and the E-shaped magnetic core are combined.

FIG. 27 is a top view of the same.

FIG. 28 is a sectional view of the completed product.

FIG. 29 (a) is a top view of the air-core coil before winding, and FIG.

FIG. 30 is a top view of the air-core coil.

FIG. 31 is a top view of another example of the air-core coil.

FIG. 32 is an explanatory view showing inconvenience of a connection portion of a terminal of the air-core coil.

FIG. 33 is an explanatory view showing a state where a spacer is interposed in a connection portion of a terminal of the air-core coil.

FIG. 34 is an exploded perspective view showing a choke coil according to a seventh embodiment of the present invention.

FIG. 35 is a perspective view showing a state where the air-core coil and the terminal block are combined.

FIG. 36 is a perspective view of a state where the airless coil, the terminal block and the E-shaped magnetic core are combined.

FIG. 37 is a perspective view showing a state in which an insulating sheet is further incorporated.

FIG. 38 is a perspective view of the finished product.

FIG. 39 is a sectional view of the same.

FIG. 40 is a top view showing a modification of the E-shaped core.

FIG. 41 is a top view showing a state where an air core coil is combined with the magnetic core.

FIG. 42 is an exploded perspective view showing a conventional choke coil.

FIG. 43 is a perspective view of the same magnetic core before being combined.

FIG. 44 is a perspective view of the completed product.

FIG. 45 is a sectional view of the same.

FIG. 46 is a top view of the same core removed.

[Explanation of symbols]

 REFERENCE SIGNS LIST 20 air core coil 21 plate conductor 22, 23 terminal 24 terminal block 25 arc-shaped piece 26 triangular piece 27 stepped portion 28, 29 terminal hole 30, 31 terminal groove 32 closed magnetic path magnetic core 33 EE type magnetic core 34 center magnetic leg 35 outer magnetic field Leg 36 Common magnetic leg 37 Notch 38 Magnetic gap 39 Wall piece 40 Winding jig 41 Cylindrical body 42 Vertical groove 43 Tapered part 44 E-shaped core 45 I-shaped core 46 Notch 47 Depression 48 T-shaped core 49 U-shaped core 50 Extension portion 51 Bend portion 52 Outer frame 53 Engagement groove 54 Depressed portion 55 Through hole 56 Insulating sheet 57 Spacer 58 Support projection 59 Tapered notch 60 Engagement piece

──────────────────────────────────────────────────続 き Continuation of front page (56) References JP-A-6-177692 (JP, A) JP-A-5-226157 (JP, A) JP-A-7-32912 (JP, U) (58) Survey Field (Int.Cl. ⁷ , DB name) H01F 17/00-17/08 H01F 27/28-27/32

Claims (25)

(57) [Claims] 1. A closed magnetic circuit core having a center magnetic leg, an outer magnetic leg, and a common magnetic leg. At least one of the terminals connected to both ends of the plate-shaped conductor of the air-core coil and provided on the inner peripheral portion of the air-core coil is provided on at least one of the common magnetic legs of the closed magnetic core. Drawn out through the notch
In this notch, the inner periphery of the air core coil and the closed magnetic core
The insulator layer interposed between the center magnetic leg and the notch
Integral insulation layer and integral insulation layer
Pull the body layer from the lower surface of the air core coil and the inner circumference of the air core coil.
Choke coil interposed between the output terminals . 2. The choke coil according to claim 1, wherein the closed magnetic path magnetic core is constituted by a combination of EE type, EI type or TU type. 3. The choke coil according to claim 1, wherein a magnetic gap is provided in a center magnetic leg as a closed magnetic circuit core. 4. The choke coil according to claim 1, wherein the cross section of the central magnetic leg of the closed magnetic circuit core is circular, oval or elliptical. 5. A concave portion, a notch or a hole is provided in a portion corresponding to a terminal inside a common magnetic leg on a side where a notch is not provided in a common magnetic leg of a closed magnetic circuit core. 2. The choke coil according to 1. 6. An EI type magnetic core is used as a closed magnetic circuit core,
Choke coil according to claim 1, the notch withdrawing the inner terminal of the air-core coil provided on the I-shaped core. 7. The thickness of the common magnetic leg on the side of the common magnetic leg on which a notch for extracting a terminal is provided as the closed magnetic core is 1
When the thickness of the common magnetic leg on the side where the notch is not provided is set to 0.
The choke coil according to claim 1, wherein the choke coil is 65 to 0.9. 8. The choke coil according to claim 1, wherein the air-core coil is formed of a self-fusing flat rectangular insulated conductor. 9. The choke coil according to claim 1, wherein the air-core coil has a circular shape, an elliptical shape, or an elliptical shape that matches the shape of the center magnetic leg of the closed magnetic circuit core. 10. The choke coil according to claim 1, wherein both ends of the plate-shaped conductor constituting the air-core coil are bent so as to project inward and outward. 11. The choke coil according to claim 1, wherein a spacer is interposed between a connection portion of a terminal connected to both ends of the air-core coil and a plate-shaped conductor of the air-core coil. 12. The choke coil according to claim 8, wherein the distance from the portion where the terminal is connected to the end as the air-core coil is slightly increased. 13. The choke coil according to claim 1, wherein the insulator layer interposed between the inner peripheral portion of the air-core coil and the center magnetic leg of the closed magnetic circuit core has a cylindrical shape that fits into the center magnetic leg. 14. An inner peripheral portion of the air-core coil and the inside of the closed magnetic core.
An insulator layer interposed between the magnetic core and the closed magnetic core
With the insulator layer that fits into the notch of the common magnetic leg
The two insulator layers are used to hold the terminals at both ends of the air-core coil.
The choke coil according to claim 1, wherein the terminal block is a terminal block . 15. An inner peripheral portion of an air-core coil at an outer end of a terminal block.
Holding the outer peripheral surface of the air core coil with the insulator layer
15. The choke coil according to claim 14, wherein a piece is provided . 16. A wall piece for holding an outer peripheral surface of an air core coil.
The choke coil according to claim 15, wherein the choke coil is provided with a taper . 17. Two terminals are insert-molded on a terminal block.
And draw both terminals outward from the same direction.
15. The choke coil according to claim 14 . 18. An insulator at an inner peripheral portion of an air core coil of a terminal block.
The bent portions at both ends of the air-core coil are engaged with the layer and the wall piece.
Item 16. The choke coil according to Item 15 . 19. A terminal block connected to both ends of an air-core coil.
The choke coil according to claim 14, further comprising a terminal guide portion . 20. An outer frame is provided integrally with the terminal block, and at least
Also incorporates a magnetic core with both outer magnetic legs from below the outer frame.
15. The choke coil according to claim 14, wherein: 21. A part of the outer frame is in contact with the outer peripheral portion of the air-core coil.
A guide section is provided to guide connected terminals, and both terminals are
21. The choke coil according to claim 20, wherein the choke coil is drawn out to the opposite side . 22. A set from above inside the four corners of the outer frame.
21. The holding device according to claim 20, further comprising a holding portion for holding the inserted magnetic core.
Choke coil. 23. When the outer frame incorporates a closed magnetic core,
Claims that have a height that covers the outer surface of the outer magnetic leg side
22. The choke coil according to 21 . 24. A closed magnetic path core having a circular center magnetic leg.
Air core coil to be incorporated into this closed magnetic circuit core.
The shape of the inner peripheral portion of the
Only the distance from the side surface of the center magnetic leg is about 2
The length is at least twice as large and the other part is a circle similar to the central magnetic leg
The choke coil according to claim 1, wherein the choke coil has a circular shape . 25. An air core is provided on the inner surfaces of both outer magnetic legs of the closed magnetic circuit core.
The concave portion for fitting the outer periphery of the coil is provided.
Choke coil.