JP3361753B2 - Trance - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transformer using a thin rectangular flat copper wire.

[0002]

2. Description of the Related Art In a high-voltage transformer for lighting a high-intensity discharge lamp, for example, a high voltage of 15 kV or more is generated in a high-voltage output winding and a flowing current is relatively large. Therefore, it is necessary to make the cross-sectional area of the wire material used as large as possible and to ensure the withstand voltage.
As shown in (A) and (B), a multilayer high voltage output is provided around a resin-made cylindrical bobbin 30 via an insulating sheet 31.
It is common to secure electrical specifications by a structure of winding the winding 32 or a structure of winding using a split bobbin (not shown).

On the other hand, if the windings are arranged in a single layer, the thickness can be reduced, but if a thick wire is used to increase the current capacity, the entire coil becomes long. Therefore, as shown in FIGS. 6C and 6D, a structure has been devised in which a thin wire 33 is wound around the bobbin 30 in a plurality of layers and connected in parallel.

Further, as shown in FIGS. 6 (E) and 6 (F),
For the structure of winding the coil in one layer, see the rectangular copper wire 34
Also, a structure in which the bobbin 30 is edgewise wound so that the narrow surface thereof is the inner circumference and the outer circumference is also adopted.

[0005]

As shown in FIGS. 6A and 6B, in the structure in which the insulating sheet 31 is provided for each layer, the manufacturing process is complicated, the manufacturing cost is high, and the thickness is thin. The shape is not suitable for conversion.

Further, as shown in FIGS. 6C and 6D,
In a structure in which a plurality of thin wire rods 33 are wound in a plurality of layers and the respective wire rods are connected in parallel with each other, the width of the coil changes due to variations in the finished diameter of the wire rods 33, so a margin is required in the width of the bobbin 30 in the winding core direction. Becomes For this reason, when winding the second and subsequent layers, depending on the finished state of the lower winding, the wire rod 33 may drop due to winding disorder, which may cause a rare short. Further, since the same winding is wound in a plurality of layers, it takes a very long winding time, which causes a cost increase. Further, it is difficult to reduce the thickness.

Further, as shown in FIGS. 6 (E) and 6 (F),
Even when the rectangular copper wire 34 is used, only a circular coil can be formed, and it is difficult to reduce the thickness.

In view of the above problems, the present invention provides a transformer that can be made thinner than the conventional transformer.

[0009]

A transformer according to claim 1 is
Using a rectangular copper wire, the narrow surface of the rectangular copper wire is the inner circumference of the coil,
A coil formed into a cylindrical shape having an outer peripheral surface and a substantially oval cross section is used as a high-voltage output winding, and the outer periphery of the coil is a cross section.
Shape covered with a cylindrical insulating cover substantially elliptic, the insulating cover
Wrap a flat copper wire other than the above flat copper wire on the outer surface of the
With the low voltage input winding, the cylindrical insulation cover
The winding position of the low-voltage input winding and the
Is provided with a positioning guide for
It is formed by protruding to the outside of the insulating cover and is used for positioning
Groove for fitting the middle part of the low-voltage input winding in the middle part of the guide
And the low-voltage input winding of the positioning guide
The lateral grooves that are cut in from both ends in the winding direction
And from the lateral groove to the tip of the positioning guide
Has a vertical groove formed, and the low-voltage input winding terminal is
Also, it is fitted and fixed in the vertical groove .

As described above, the narrow surface of the rectangular copper wire is the coil.
Cylindrical shape that has inner and outer circumferences and a cross section that is approximately oval
The coil formed on the
Cover the circumference with a cylindrical insulation cover, and
By winding a rectangular copper wire different from the rectangular copper wire,
Since it is a pressure input winding, the high voltage output winding can be wound in a single layer.
You can earn more and secure the cross-sectional area to increase the current capacity.
It is possible to have it, which makes it possible to reduce the size and manufacturing process.
The coil shape can be simplified and the shape of the coil can be elliptical.
With this, thinning can be achieved.

If the positioning guide is provided, the
When winding the pressure input winding, the middle part of the winding is guided.
At the same time, the end parts at both ends are fitted in the notched lateral groove.
After bending, bending and fitting along the vertical groove,
It can be easily wound and fixed on the insulating cover.

The transformer of claim 2 is the same as that of claim 1.
The low-voltage input winding is wound on the end side of the insulation cover in the winding core direction.

As described above, when the low voltage input winding is wound around a portion of the insulating cover that is offset to one side from the center, the side on which the low voltage input winding is wound serves as the low voltage side of the high voltage output winding. The safety of the above is improved.

The transformer of claim 3 is the transformer of claim 1 or 2.
In, the coil wound as the high-voltage output winding,
A high-resistance ferrite core having a substantially elliptic rod shape whose cross-sectional shape matches the inner circumference of the coil is directly incorporated without an insulator, and the core is sandwiched between both ends of the rod-shaped core. It is characterized in that a U-shaped ferrite core is provided.

As described above, the high-voltage output winding can be made thinner by directly inserting the high-resistance ferrite core into the high-voltage output winding without an insulating material. Also,
As in the case of using the U and U cores, fixing means for fixing these cores in the winding core direction is not required, and the size can be reduced accordingly.

[0016]

PREFERRED EMBODIMENTS FIG. 1 (A) is used Oite the present invention
FIG. 1 (B) is an end view showing an example of a coil
The cross-sectional view and FIG. 1C are end views of the rectangular copper wire. 3 is a coil formed by winding the rectangular copper wire 2. The coil 3 has a substantially oval cross-section in a cross section orthogonal to the winding core. As shown in FIG. 1C, the rectangular copper wire 2 is wound (edgewise) so that the narrow width surfaces 2 a and 2 b thereof are the inner circumference and the outer circumference surface of the coil 3.

As described above, the rectangular copper wire 2 is used, and the coil 3 is connected to the high voltage of the transformer so that the cross-sectional shape of the flat copper wire 2 becomes substantially oval.
The transformer can be made thinner by using it for the output winding . Further, since the rectangular copper wire 2 is used, the cross-sectional area of the wire can be secured, the number of turns can be secured, and the length in the winding core direction can be shortened.

2A, 2B, and 2C are a plan view, a front view, and a side view, respectively, showing an embodiment of a transformer according to the present invention constructed by using the above coil structure. 3 (A) is a longitudinal sectional view of this transformer, and FIG. 3 (B).
FIG. 4 is a sectional view taken along line EE of FIG. In FIG. 3, 3
Is a high-voltage output winding composed of a coil formed by winding the rectangular copper wire 2 into a tubular shape having a substantially oval cross section as described above.

In FIGS. 2 and 3, reference numeral 4 is a resin-made insulating cover having a tubular shape with a substantially oval cross section, and the insulating cover 4 is attached so as to cover the high-voltage output winding 3. Terminal blocks 4a, 4 of the high-voltage output winding 3 are provided at both ends of the insulating cover 4.
b is integrally formed, and terminals 5 and 6 connecting both ends of the high voltage output winding 3 are fixed to these terminal blocks 4a and 4b.

A low-voltage input winding 7 made of a rectangular copper wire is provided on the outer periphery of the high-voltage output winding 3 in order to improve insulation safety.
The insulating cover 4 is wound to the end side from the center in the winding core direction. That is, the low voltage input winding 7 side of the high voltage output winding 3 becomes the low voltage side of the high voltage output winding 3. The low voltage input winding 7 is wound a plurality of times (twice in this example), and in this example, the input voltage is 380 V and the output voltage is 24 kV.

A positioning guide 8 for winding the low-voltage input winding 7 and for drawing out the terminal is integrally provided on the outer periphery of the cylindrical insulating cover 4. The positioning guide 8
Are provided so as to project to the outside of the insulating cover 4. At least one groove 8a for fitting and positioning the intermediate portion of the low-voltage input winding 7 is provided at the intermediate portion of the guide 8. Also,
As shown in FIG. 4, the root portions of both ends of the guide 8 are provided with notch-shaped lateral grooves 8b and 8c for fitting and positioning the ends of the low-voltage input winding 7, and the roots of the respective lateral grooves 8b and 8c are provided. Vertical grooves 8d and 8e are formed from the portion to the tip of the guide 8. These vertical grooves 8d and 8e are formed toward the opposite sides so that the tangential surface of the outer periphery of the insulating cover 4 is opened. The end of the low voltage input winding 7 is easily fixed by first fitting it into the lateral grooves 8b and 8c as indicated by arrow X and then bending it so as to fit into the longitudinal grooves 8d and 8e as indicated by arrow Y. .

In FIG. 3 (A), 9 is a rod-shaped core inserted in the coil wound as the high-voltage output winding 3. The core 9 of this example has a substantially elliptical cross-sectional shape that is slightly smaller than the inner peripheral shape of the coil. By using a high resistance ferrite core as the core 9, the core 9 can be directly incorporated into the high voltage output winding 3 without an insulator. 10 is a rod-shaped core at both ends so as to sandwich the core,
It is a U-shaped ferrite core that is attached via an insulating material 11 to form a magnetic circuit.

As shown in FIG. 2, the legs 10a, 10a of the U-shaped ferrite core 10 are provided at both ends of the insulating cover 4.
A pair of sandwiching pieces 4c for sandwiching and fixing b are provided at both ends of the insulating cover 4.

The insulating cover 4 and the core 10 are fixed by an adhesive (not shown), and more generally, the terminals 7a and 7b of the low voltage input winding 7 and the terminal 5 of the high voltage output winding 3 are Parts other than 6 are molded with resin (not shown).

FIG. 5 (A) is a sectional view showing another embodiment of the present invention, and FIG. 5 (B) is a sectional view taken along the line F-F in FIG. 5 (A). Instead of the U-shaped core 10, two U-shaped high-resistance ferrite cores 13, 1
3 is combined through the insulating material 14, and other structures are as described above. In this case, means (not shown) for fixing the ferrite cores 13, 13 is required.

When the embodiment of FIG. 5 is compared with the embodiment of FIG. 3, by combining the rod-shaped core 9 and the U-shaped core 10 as shown in FIG. There is an advantage that the fixing means for the cores 13 and 13 is not required and the overall shape can be reduced accordingly.

In the present invention, the substantially oval shape, which is the cross-sectional shape of the coil, includes, for example, an elliptical shape or an oval shape that approximates an oval shape.

[0028]

According to the transformer of the first aspect of the present invention, a coil formed in a cylindrical shape in which the narrow width surface of the rectangular copper wire serves as the inner and outer peripheral surfaces of the coil and the cross section is substantially oval is used for the high voltage output winding. ,
The outer circumference of the coil is covered with a cylindrical insulating cover, and the insulating cover is covered.
Wrap a flat copper wire other than the above flat copper wire on the outer surface of the
It is a low voltage input winding and a high voltage output winding.
Even if the wire is wound one layer, the number of turns can be increased, and the cross-sectional area can be secured to have a current capacity, which enables downsizing and simplification of the manufacturing process, and the coil shape to be substantially oval. By doing so, thinning can be achieved.

Also, a low pressure is applied to the outer surface of the cylindrical insulating cover.
Winding position of input winding and positioning for terminal drawing
Is provided with an insulating cover.
Of the positioning guide, which is formed by protruding to the outside of the
If there is a groove that fits the middle part of the low voltage input winding
Together, in the core direction of the low-voltage input winding of the positioning guide
It has lateral grooves cut from both ends, and
Formed from the lateral groove to the tip of the positioning guide
It has a vertical groove, and the low voltage input winding terminal is in the horizontal groove and the vertical groove.
Since it was fitted and fixed, the low voltage input winding
When winding, the middle part of the winding is guided and both
Insert the end part at the end into the notched lateral groove and then fold it.
Easy to insulate by bending and fitting along the vertical groove
It can be wound and fixed on the cover.

According to a second aspect of the present invention , in the first aspect, the low voltage input winding is wound on the end side of the insulating cover in the longitudinal direction. Therefore, the side on which the low voltage input winding is wound is high voltage. By setting the low-voltage side of the output winding, the creepage distance between the high-voltage side of the high-voltage output winding and the low-voltage input winding can be increased, and the safety in insulation is improved.

According to a third aspect of the present invention, the coil wound as the high-voltage output winding according to the first or second aspect has a substantially elliptic rod shape whose cross-sectional shape matches the inner circumference of the coil. Since a high-resistance ferrite core was directly incorporated without using an insulator, and a U-shaped ferrite core was provided at both ends of the rod-shaped core so as to sandwich the core,
The high-voltage output winding can be made thinner by directly inserting the high-resistance ferrite core into the high-voltage output winding without an insulator. Further, unlike the case of using the U and U cores, a fixing means for fixing these cores in the winding core direction becomes unnecessary, and the size can be reduced accordingly.

[Brief description of drawings]

1 (A) is an end view showing one example of a coil used Oite the present invention, (B) is its D-D sectional view, (C) is an end view showing an example of a rectangular copper wire used in the present invention Is.

2A, 2B, and 2C are a plan view, a front view, and a side view, respectively, showing an embodiment of a transformer according to the present invention configured by using the above coil structure.

3A is a longitudinal sectional view of this transformer, and FIG. 3B is a sectional view taken along line EE of FIG.

4 is a perspective view showing a positioning guide in the embodiment of FIGS. 2 and 3. FIG.

5A is a vertical sectional view of a transformer according to another embodiment of the present invention, and FIG. 5B is a sectional view taken along line FF of FIG.

6 (A) is an end view showing an example of a high voltage output winding of a conventional transformer, (B) is a sectional view thereof, (C) the conventional bets
An end view showing another example of the high voltage output winding of the lance , (D) is a sectional view thereof, (E) is an end view showing another example of the conventional transformer high voltage output winding , and (F) is a sectional view thereof. It is a figure.

[Explanation of symbols]

1: bobbin, 2: flat copper wire, 3: coil (high voltage output winding), 4: insulating cover, 5, 6: terminal, 7: low voltage input winding, 8: positioning guide, 8a: groove, 8b, 8c: lateral groove, 8d, 8e: vertical groove, 9: bar-shaped core, 10: U-shaped core, 11, 14: insulating material, 13: U-shaped core

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Claims (3)

(57) [Claims] 1. A rectangular copper wire is used, and the narrow surface of the rectangular copper wire is
The inner and outer peripheral surfaces of the il and the cross section are approximately oval.
Formed into a tubular shapeThe coil is a high voltage output winding, A cylindrical insulating cover having a substantially oval cross section around the outer circumference of the coil.
Cover with On the outer surface of the insulating cover, a rectangular copper wire different from the rectangular copper wire is attached.
By winding, it becomes a low voltage input winding, Winding position of the low voltage input winding on the outer surface of the cylindrical insulating cover
And a positioning guide for pulling out the terminal, The positioning guide is projected outside the insulating cover.
Formed, An intermediate part of the low voltage input winding is provided in the middle part of the positioning guide.
With a groove to fit the minute, From both ends in the winding core direction of the low-voltage input winding of the positioning guide.
Each has a lateral groove provided in a notch shape, and the lateral groove
From the vertical groove formed from the to the tip of the positioning guide
Has a low voltage input winding terminal fitted in the lateral groove and the vertical groove
Fixed Characterized byTrance. 2. The method according to claim 1, The lower side of the insulating cover is closer to the end side than the center in the winding core direction.
Characterized by winding a piezo input windingTrance. 3. The high-resistance ferrite core in a coil wound as the high-voltage output winding, the high-resistance ferrite core having a substantially elliptic rod shape whose cross-sectional shape matches the inner circumference of the coil, according to claim 1 . The transformer is characterized in that it is directly incorporated without interposing, and a U-shaped ferrite core is provided at both ends of the rod-shaped core so as to sandwich the core.