JP3671171B2 - Coil device and manufacturing method thereof - Google Patents
Coil device and manufacturing method thereof Download PDFInfo
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- JP3671171B2 JP3671171B2 JP2002245026A JP2002245026A JP3671171B2 JP 3671171 B2 JP3671171 B2 JP 3671171B2 JP 2002245026 A JP2002245026 A JP 2002245026A JP 2002245026 A JP2002245026 A JP 2002245026A JP 3671171 B2 JP3671171 B2 JP 3671171B2
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Description
【0001】
【発明の属する技術分野】
本発明は、各種交流機器に装備されるリアクターや変圧器等において磁気回路を形成するために用いられる鉄心、及びこれを用いたコイル装置、並びにこれらの製造方法に関するものである。
【0002】
【従来の技術】
従来、リアクターや変圧器等に用いられる鉄心として、磁気特性に優れると共に量産性の高い巻き鉄心が広く採用されている。
リアクターに用いられる巻き鉄心においては、磁路中に磁気ギャップ部を設けて直流重畳特性を安定させることが行なわれており、更には、磁気ギャップ部を複数箇所に分散させることによって、直流重畳特性の更なる安定化、磁気ギャップ部からの漏れ磁束の抑制、漏れ磁束による渦電流損の低減などが図られている。
【0003】
図13は、従来の巻き鉄心(10)を具えたリアクター用のコイル装置を表わしている。該コイル装置においては、鉄心(10)の磁路中に複数の磁気ギャップ層(41)が介在し、該磁路を包囲して、ボビン(55)にコイル(56)を巻装してなるコイルアセンブリ(57)が装着されている。
【0004】
図9〜図12は、上記コイル装置の製造方法を表わしている。
図9の如く、金属製の帯板を巻回して環状の巻き鉄心部材(22)を作製した後、該巻き鉄心部材(22)を、図中に破線で示す複数の切断線B−Bに沿って分断することにより、図10に示す如く、一対のC字状の分割鉄心片(23)(23)と、複数のI字状(直方体状)の分割鉄心片(24)(24)(24)とを得る。
【0005】
次に、図11に示す如く、C字状分割鉄心片(23)とI字状分割鉄心片(24)の対向面間、及びI字状分割鉄心片(24)どうしの対向面間に、磁気ギャップ層(41)を介在させて、一方のC字状分割鉄心片(23)に複数のI字状分割鉄心片(24)を接合して、U字状のコアブロックを得る。
その後、図12に示す如く、前記U字状コアブロックに対し、ボビン(55)にコイル(56)を巻装してなるコイルアセンブリ(57)を装着した後、図13に示す如く該U字状コアブロックに他方のC字状分割鉄心片(23)を接合して、コイル装置を完成する。
尚、図13に示すコイル装置においては、締結バンド(6)によって鉄心(10)の一体化構造を補強している。
【0006】
【発明が解決しようとする課題】
しかしながら、図13に示すコイル装置においては、8箇所に磁気ギャップ部を形成するために、図9及び図10に示す巻き鉄心部材(22)の切断工程で、8箇所を切断せねばならず、磁気ギャップ部の数に応じて、切断の工数が増大する問題があった。
又、磁気ギャップ部の数に応じて、図9に示す巻き鉄心部材(22)が磁気ギャップ部介在方向に長大化するため、この様な横長の巻き鉄心部材(22)の製造においては、帯板を巻回する作業で帯板が弛み易くなって、巻き鉄心部材(22)の巻厚寸法にバラツキが生じる。この結果、図13に示す如くボビン(55)の中央孔の寸法に余裕を持たせる必要が生じ、これによって装置の大型化を招く問題があった。
【0007】
そこで本発明の目的は、磁気ギャップ部の数に拘わらず少ない切断工数で製造することが可能であり、然も、厚さ寸法のバラツキを抑制することが可能な鉄心、該鉄心を用いたコイル装置、並びに該鉄心及び該コイル装置の製造方法を提供することである。
【0008】
【課題を解決する為の手段】
本発明に係るコイル装置においては、金属製の帯板を巻回して作製した環状の巻き鉄心部材 (21) を分断してなる一対のC字状分割鉄心片 ( 2 )( 2 ) と、該一対のC字状分割鉄心片 ( 2 )( 2 ) の切断面の間に介在する1或いは複数個の直方体状の積層鉄心片 ( 3 ) と、C字状分割鉄心片 ( 2 ) と積層鉄心片 ( 3 ) の対向面間並びに積層鉄心片 ( 3 ) どうしの対向面間に介在する磁気ギャップ層 ( 4 ) とによって、環状の鉄心 ( 1 ) が構成されると共に、該鉄心 ( 1 ) によって形成される磁路を包囲して、ボビン (53) の周囲にコイル (52) を巻装してなるコイルアセンブリ (57) が装着されている。
前記ボビン (53) には、前記1或いは複数の積層鉄心片 ( 3 ) がインサートモールドによって埋設され、該積層鉄心片 ( 3 ) がボビン (53) に保持された状態で一対のC字状分割鉄心片 ( 2 )( 2 ) の切断面の間に介在すると共に、C字状分割鉄心片 ( 2 ) と積層鉄心片 ( 3 ) の対向面間並びに積層鉄心片 ( 3 ) どうしの対向面間にボビン (53) の一部が介在して、前記磁気ギャップ層 ( 4 ) を形成している。
【0009】
本発明に係るコイル装置の製造方法は、上記本発明のコイル装置を製造する方法であって、
金属製の帯板を巻回して環状の巻き鉄心部材 (21) を作製し、該巻き鉄心部材 (21) を分断して一対のC字状分割鉄心片 ( 2 )( 2 ) を得る工程と、
鉄板片 (31) を積層してなる直方体状の積層鉄心片 ( 3 ) を1或いは複数個作製した後、インサートモールドによってボビン (53) 中に前記1或いは複数個の積層鉄心片 ( 3 ) を埋設すると共に、ボビン (53) の一部によって前記磁気ギャップ層 ( 4 ) を形成する工程と、
前記一対のC字状分割鉄心片 ( 2 )( 2 ) の対向する切断面の間に、前記1或いは複数個の積層鉄心片 ( 3 ) が埋設されたボビン (53) を介在させることにより、前記鉄心 ( 1 ) を組み立てる工程
とを有している。
【0012】
上記本発明のコイル装置及びその製造方法によれば、インサートモールドによって複数の積層鉄心片(3)をボビン(53)中に埋設することが可能であり、該ボビン(53)を一対のC字状分割鉄心片(2)(2)の切断面の間に介在させて、鉄心(1)を組み立てることが出来るので、一対のC字状分割鉄心片(2)(2)に対して複数の積層鉄心片(3)を固定する作業と、鉄心(1)に対してコイル(52)を装着する作業とが、共通の工程によって実施されることとなり、工数の削減が図られる。又、C字状分割鉄心片(2)と積層鉄心片(3)の対向面間、並びに積層鉄心片(3)どうしの対向面間に形成される磁気ギャップ層(4)の厚さ、即ちギャップ寸法は、ボビン(53)のインサートモールドによって高精度化することが可能である。然も、積層鉄心片(3)はボビン(53)中に埋設されて、ボビン(53)内に確実に保持されるので、コイル(52)に通電したときのうなり音の発生を抑制することが出来る。
【0013】
【発明の効果】
本発明に係るコイル装置及びその製造方法によれば、磁気ギャップ部の数に拘わらず少ない切断工数で鉄心を製造することが可能であり、然も、鉄心の形状寸法に高い精度が得られる。
【0014】
【発明の実施の形態】
以下、本発明の実施の形態につき、図面に沿って具体的に説明する。
本発明に係るコイル装置は、図1に示す如く、環状を呈する鉄心(1)に一対のコイルアセンブリ(5)(5)を装着して構成され、鉄心(1)の磁路中には、複数の磁気ギャップ層(4)が介在して、分散型の磁気ギャップ部を形成している。
【0015】
図2〜図6は、上記コイル装置の製造方法を表わしている。
図2(a)の如く、金属製の帯板を巻回することによって、O字状(環状)の巻き鉄心部材(21)を作製した後、該巻き鉄心部材(21)を、図中に破線で示す1本の切断線A−Aに沿って分断することにより、同図(b)に示す如く、左右一対のC字状分割鉄心片(2)(2)を得る。
【0016】
一方、図3に示す如く、矩形を呈する複数枚の鉄板片(31)をプレス加工によって作製した後、これら複数枚の鉄板片(31)を重ね合わせて積層方向に加圧することにより、直方体状の積層鉄心片(3)を得る。該積層鉄心片(3)は、図10に示す従来のI字状分割鉄心片(24)に対応するものであるが、該分割鉄心片(24)よりも高精度の形状寸法を得ることが出来る。
【0017】
その後、図4に示す如く、一対のC字状分割鉄心片(2)(2)の切断面の間に、複数個(本実施例では合計6個)の積層鉄心片(3)を配置する。そして、図5に示す如く、C字状分割鉄心片(2)と積層鉄心片(3)の対向面間、及び積層鉄心片(3)どうしの対向面間に、磁気ギャップ層(4)を介在させて、一方のC字状分割鉄心片(2)に対して複数の積層鉄心片(3)を一体化し、U字状のコアブロックを得る。
【0018】
その後、図6に示す如く、前記U字状コアブロックに対し、ボビン(55)にコイル(56)を巻装してなる一対のコイルアセンブリ(57)(57)を装着した後、図1に示す如く該U字状コアブロックに対して他方のC字状分割鉄心片(2)を接合することにより、8つの磁気ギャップ部を有するコイル装置を完成する。
尚、図1に示すコイル装置においては、締結バンド(6)によって鉄心(1)の一体化構造を補強している。
【0019】
上記本発明の鉄心(1)の製造方法においては、磁気ギャップ部の数に拘わらず、図2に示す如く巻き鉄心部材(21)に対する切断箇所は2箇所であって、磁気ギャップ部の数が増えても、切断工数に変化はない。又、磁気ギャップ部の数に拘わらず、一対のC字状分割鉄心片(2)(2)を得ることが可能な必要最小限の形状寸法の巻き鉄心部材(21)を作製すればよいので、金属製の帯板を巻回して巻き鉄心部材(21)を製造する工程において帯板が弛む虞はない。
更に又、積層鉄心片(3)は、図3に示す如く複数枚の鉄板片(31)を積層し、これをプレスすることによって、容易に作製することが出来、然も積層厚さに高い精度が得られる。
従って、ボビン(51)の中央孔の寸法に与えるべき余裕を従来よりも小さくすることが出来、これによってボビン(51)の小型化、ひいてはコイル装置の小型化が図られる。
【0020】
図8に示すコイル装置は、鉄心(1)の構成において図1に示すものと同一であるが、鉄心(1)を構成している複数の積層鉄心片(3)が、図7に示す如く予めボビン(53)中に埋設されているものである。
ボビン(53)中に複数の積層鉄心片(3)を埋設する工程は、インサートモールドによって実施される。尚、該ボビン(53)においては、その両側にC字状分割鉄心片(2)の端部が嵌入すべき凹部(54)(54)が形成されている。
【0021】
該コイル装置においては、図8に示す如く、複数の積層鉄心片(3)が埋設されたボビン(53)を一対のC字状分割鉄心片(2)(2)の切断面の間に介在させて、鉄心(1)が組み立てられているので、その製造工程においては、一対のC字状分割鉄心片(2)(2)に対して複数の積層鉄心片(3)を固定する作業と、鉄心(1)に対してコイル(52)を装着する作業とが、共通の工程によって同時に実施されることとなり、工数の削減が図られる。
又、C字状分割鉄心片(2)と積層鉄心片(3)の対向面間、並びに積層鉄心片(3)どうしの対向面間に形成される磁気ギャップ層(4)の厚さ、即ちギャップ寸法は、ボビン(53)のインサートモールドによって高精度化を図ることが可能である。
然も、積層鉄心片(3)はボビン(53)中に埋設されて、ボビン(53)内に確実に保持されるので、コイル(52)に通電したときのうなり音の発生を抑制することが出来る。
【0022】
尚、本発明の各部構成は上記実施の形態に限らず、特許請求の範囲に記載の技術的範囲内で種々の変形が可能である。例えば、上記実施例においては、磁気ギャップ部の数を8つとしているが、これに限らず任意数の磁気ギャップ部を設けることが可能である。又、ギャップ寸法についても、必ずしも同一値とする必要はなく、異なるギャップ寸法を有する複数の磁気ギャップ部を設けることが可能である。更に、2つのコイルアセンブリ(5)(5)を互いに異なる巻数に形成することも可能である。
更に又、鉄心(1)を構成するC字状分割鉄心片(2)と積層鉄心片(3)を同一の材質から形成する例に限らず、異なる材質の採用によって、鉄心(1)に2つの材質の合成特性を得ることも可能である。
【図面の簡単な説明】
【図1】本発明に係るコイル装置の一部破断正面図である。
【図2】巻き鉄心部材の切断工程を示す図である。
【図3】積層鉄心片の製造工程を示す図である。
【図4】一対のC字状分割鉄心片の間に複数の積層鉄心片を配置する工程を示す図である。
【図5】一方のC字状分割鉄心片に複数の積層鉄心片を接合する工程を示す図である。
【図6】コイルアセンブリの装着工程を示す図である。
【図7】複数の積層鉄心片が埋設されたボビンの断面図である。
【図8】該ボビンを装着したコイル装置の一部破断正面図である。
【図9】従来のコイル装置の製造に用いられている巻き鉄心部材の正面図である。
【図10】該巻き鉄心部材を分断する工程を示す図である。
【図11】一方のC字状分割鉄心片に複数のI字状分割鉄心片を接合する工程を示す図である。
【図12】コイルアセンブリの装着工程を示す図である。
【図13】従来のコイル装置の一部破断正面図である。
【符号の説明】
(1) 鉄心
(2) C字状分割鉄心片
(3) 積層鉄心片
(4) 磁気ギャップ層
(5) コイルアセンブリ
(51) ボビン
(52) コイル
(21) 巻き鉄心部材
(31) 鉄板片
(53) ボビン[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an iron core used for forming a magnetic circuit in a reactor, a transformer or the like equipped in various AC devices, a coil device using the same, and a method for manufacturing the same.
[0002]
[Prior art]
Conventionally, wound cores that are excellent in magnetic properties and high in mass productivity have been widely used as iron cores used in reactors, transformers, and the like.
In a wound iron core used in a reactor, a magnetic gap portion is provided in a magnetic path to stabilize the DC superposition characteristics. Furthermore, by dispersing the magnetic gap portions in a plurality of locations, the DC superposition characteristics are achieved. Further stabilization, suppression of leakage magnetic flux from the magnetic gap portion, reduction of eddy current loss due to leakage magnetic flux, and the like are attempted.
[0003]
FIG. 13 shows a coil device for a reactor having a conventional wound iron core (10). In the coil device, a plurality of magnetic gap layers (41) are interposed in the magnetic path of the iron core (10), surround the magnetic path, and the coil (56) is wound around the bobbin (55). A coil assembly (57) is mounted.
[0004]
9-12 represents the manufacturing method of the said coil apparatus.
As shown in FIG. 9, after a metal strip is wound to produce an annular wound core member (22), the wound core member (22) is cut into a plurality of cutting lines BB indicated by broken lines in the figure. As shown in FIG. 10, a pair of C-shaped split core pieces (23) (23) and a plurality of I-shaped (cuboid) split core pieces (24) (24) ( 24) and get.
[0005]
Next, as shown in FIG. 11, between the facing surfaces of the C-shaped split core pieces (23) and the I-shaped split core pieces (24) and between the facing surfaces of the I-shaped split core pieces (24), A plurality of I-shaped divided core pieces (24) are joined to one C-shaped divided core piece (23) with the magnetic gap layer (41) interposed therebetween to obtain a U-shaped core block.
Thereafter, as shown in FIG. 12, a coil assembly (57) in which a coil (56) is wound around a bobbin (55) is attached to the U-shaped core block, and then the U-shaped core block as shown in FIG. The other C-shaped split core piece (23) is joined to the cylindrical core block to complete the coil device.
In the coil device shown in FIG. 13, the integrated structure of the iron core (10) is reinforced by the fastening band (6).
[0006]
[Problems to be solved by the invention]
However, in the coil device shown in FIG. 13, in order to form the magnetic gap portion at 8 places, 8 places must be cut in the cutting process of the wound core member (22) shown in FIGS. 9 and 10. There is a problem that the number of man-hours for cutting increases according to the number of magnetic gap portions.
Further, since the wound core member (22) shown in FIG. 9 is elongated in the direction in which the magnetic gap portion is interposed depending on the number of magnetic gap portions, in the production of such a horizontally long wound core member (22), When the plate is wound, the band plate is easily loosened, and the winding thickness of the wound iron core member (22) varies. As a result, as shown in FIG. 13, it is necessary to provide a margin for the size of the central hole of the bobbin (55), which causes a problem of increasing the size of the apparatus.
[0007]
SUMMARY OF THE INVENTION An object of the present invention is to provide an iron core that can be manufactured with a small number of cutting steps regardless of the number of magnetic gap portions, and that can suppress variations in thickness, and a coil using the iron core. It is to provide a device and a method for manufacturing the iron core and the coil device.
[0008]
[Means for solving the problems]
In the coil device according to the present invention, a pair of C-shaped split core pieces ( 2 ) ( 2 ) formed by dividing an annular wound core member (21) produced by winding a metal strip , and One or a plurality of rectangular parallelepiped laminated core pieces ( 3 ) interposed between the cut surfaces of the pair of C-shaped divided core pieces ( 2 ) and ( 2 ) , the C-shaped divided core pieces ( 2 ), and the laminated cores facing surfaces and between the laminated core pieces piece (3) (3) How to magnetic gap layer interposed between the facing surfaces of the (4), with an annular core (1) is constituted by iron center (1) A coil assembly (57) formed by winding a coil (52) around a bobbin (53 ) is mounted so as to surround the magnetic path to be formed .
Wherein the bobbin (53), said one or plurality of stacked core sheets (3) are buried by insert molding, laminated core pieces (3) of the bobbin (53) a pair of C-shaped split in a state of being retained at with interposed between the cut surfaces of the core pieces (2) (2), C-shaped segment core pieces (2) and the opposing surface and between the laminated core pieces of the laminated core pieces (3) (3) between what was facing surfaces of the A part of the bobbin (53) is interposed in the magnetic gap layer ( 4 ) .
[0009]
A method for manufacturing a coil device according to the present invention is a method for manufacturing the coil device according to the present invention.
Winding a metal strip to produce an annular wound core member (21) , dividing the wound core member (21) to obtain a pair of C-shaped split core pieces ( 2 ) ( 2 ) ; ,
After cuboid laminated core pieces formed by iron piece (31) by stacking (3) one or a plurality prepared, wherein 1 or a plurality of laminated core pieces in the bobbin (53) by insert molding the (3) Burying and forming the magnetic gap layer ( 4 ) by a part of the bobbin (53) ;
By interposing a bobbin (53) in which the one or a plurality of laminated core pieces ( 3 ) are embedded between the opposing cut surfaces of the pair of C-shaped divided core pieces ( 2 ) ( 2 ) , Assembling the iron core ( 1 )
And have.
[0012]
According to the coil device of the present invention and the manufacturing method thereof , a plurality of laminated core pieces (3) can be embedded in the bobbin (53) by insert molding, and the bobbin (53) is paired with a pair of C-characters. Since the core (1) can be assembled by being interposed between the cut surfaces of the segmented core pieces (2) and (2), a plurality of C-shaped segmented core pieces (2) and (2) are provided with a plurality of pieces. The work of fixing the laminated core piece (3) and the work of attaching the coil (52) to the iron core (1) are carried out by a common process, thereby reducing the man-hours. Further, the thickness of the magnetic gap layer (4) formed between the facing surfaces of the C-shaped split core pieces (2) and the laminated core pieces (3) and between the opposed faces of the laminated core pieces (3), that is, The gap dimension can be made highly accurate by the insert mold of the bobbin (53). However, since the laminated iron core piece (3) is embedded in the bobbin (53) and is securely held in the bobbin (53), the generation of the beat sound when the coil (52) is energized is suppressed. I can do it.
[0013]
【The invention's effect】
According to the coil device and the manufacturing method thereof according to the present invention, it is possible to manufacture an iron core with a small number of cutting steps regardless of the number of magnetic gap portions, and high accuracy can be obtained in the shape dimension of the iron core.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
As shown in FIG. 1, the coil device according to the present invention is configured by mounting a pair of coil assemblies (5) and (5) on an annular iron core (1), and in the magnetic path of the iron core (1), A plurality of magnetic gap layers (4) are interposed to form a distributed magnetic gap portion.
[0015]
2-6 represents the manufacturing method of the said coil apparatus.
As shown in FIG. 2 (a), an O-shaped (annular) wound core member (21) is produced by winding a metal strip, and then the wound core member (21) is shown in the figure. By dividing along one cutting line AA indicated by a broken line, a pair of left and right C-shaped split core pieces (2) and (2) are obtained as shown in FIG.
[0016]
On the other hand, as shown in FIG. 3, a plurality of iron plate pieces (31) having a rectangular shape are produced by pressing, and then the plurality of iron plate pieces (31) are stacked and pressed in the stacking direction to form a rectangular parallelepiped shape. The laminated core piece (3) is obtained. The laminated core piece (3) corresponds to the conventional I-shaped divided core piece (24) shown in FIG. 10, but it is possible to obtain a more accurate shape and dimension than the divided core piece (24). I can do it.
[0017]
After that, as shown in FIG. 4, a plurality of (6 in total in this embodiment) laminated core pieces (3) are arranged between the cut surfaces of the pair of C-shaped split core pieces (2) and (2). . Then, as shown in FIG. 5, the magnetic gap layer (4) is formed between the facing surfaces of the C-shaped split core piece (2) and the laminated core piece (3) and between the opposed faces of the laminated core pieces (3). A plurality of laminated core pieces (3) are integrated with one C-shaped split core piece (2) to obtain a U-shaped core block.
[0018]
Thereafter, as shown in FIG. 6, after mounting a pair of coil assemblies (57) and (57) each having a coil (56) wound around a bobbin (55) to the U-shaped core block, FIG. As shown in the figure, the other C-shaped split core piece (2) is joined to the U-shaped core block to complete a coil device having eight magnetic gap portions.
In the coil device shown in FIG. 1, the integrated structure of the iron core (1) is reinforced by the fastening band (6).
[0019]
In the manufacturing method of the iron core (1) according to the present invention, regardless of the number of magnetic gap portions, there are two cut portions with respect to the wound iron core member (21) as shown in FIG. Even if it increases, the man-hour for cutting does not change. Moreover, it is only necessary to produce the wound core member (21) having the minimum necessary shape and dimension capable of obtaining a pair of C-shaped split core pieces (2) (2) regardless of the number of magnetic gap portions. In addition, there is no possibility that the band plate is loosened in the process of manufacturing the wound iron core member (21) by winding the metal band plate.
Furthermore, the laminated iron core piece (3) can be easily manufactured by laminating a plurality of iron plate pieces (31) as shown in FIG. Accuracy is obtained.
Therefore, the margin to be given to the dimension of the central hole of the bobbin (51) can be made smaller than before, and thereby the bobbin (51) can be downsized and the coil device can be downsized.
[0020]
The coil device shown in FIG. 8 is the same as that shown in FIG. 1 in the configuration of the iron core (1), but a plurality of laminated iron core pieces (3) constituting the iron core (1) are formed as shown in FIG. It is embedded in the bobbin (53) in advance.
The step of embedding a plurality of laminated core pieces (3) in the bobbin (53) is performed by an insert mold. In the bobbin (53), concave portions (54) and (54) into which the end portions of the C-shaped split core pieces (2) are to be fitted are formed on both sides thereof.
[0021]
In the coil device, as shown in FIG. 8, a bobbin (53) in which a plurality of laminated core pieces (3) are embedded is interposed between the cut surfaces of a pair of C-shaped divided core pieces (2) and (2). Since the iron core (1) is assembled, in the manufacturing process, the work of fixing the plurality of laminated iron core pieces (3) to the pair of C-shaped divided iron core pieces (2) (2) The work of attaching the coil (52) to the iron core (1) is performed simultaneously by a common process, and the man-hours can be reduced.
Further, the thickness of the magnetic gap layer (4) formed between the facing surfaces of the C-shaped split core pieces (2) and the laminated core pieces (3) and between the opposed faces of the laminated core pieces (3), that is, The gap dimension can be increased in accuracy by the insert mold of the bobbin (53).
However, since the laminated iron core piece (3) is embedded in the bobbin (53) and is securely held in the bobbin (53), the generation of the beat sound when the coil (52) is energized is suppressed. I can do it.
[0022]
In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, in the above-described embodiment, the number of magnetic gap portions is eight, but the number is not limited to this, and an arbitrary number of magnetic gap portions can be provided. Also, the gap dimensions do not necessarily have to be the same value, and a plurality of magnetic gap portions having different gap dimensions can be provided. Further, it is possible to form the two coil assemblies (5) and (5) with different numbers of turns.
Further, the C-shaped split core piece (2) and the laminated core piece (3) constituting the iron core (1) are not limited to the example of forming the same material, but by using different materials, the core (1) can be It is also possible to obtain composite properties of two materials.
[Brief description of the drawings]
FIG. 1 is a partially cutaway front view of a coil device according to the present invention.
FIG. 2 is a view showing a cutting process of a wound iron core member.
FIG. 3 is a diagram showing a manufacturing process of a laminated core piece.
FIG. 4 is a diagram showing a step of arranging a plurality of laminated core pieces between a pair of C-shaped split core pieces.
FIG. 5 is a diagram showing a step of joining a plurality of laminated core pieces to one C-shaped divided core piece.
FIG. 6 is a diagram showing a coil assembly mounting process;
FIG. 7 is a cross-sectional view of a bobbin in which a plurality of laminated core pieces are embedded.
FIG. 8 is a partially cutaway front view of a coil device equipped with the bobbin.
FIG. 9 is a front view of a wound iron core member used for manufacturing a conventional coil device.
FIG. 10 is a diagram showing a step of cutting the wound core member.
FIG. 11 is a diagram showing a process of joining a plurality of I-shaped divided core pieces to one C-shaped divided core piece.
FIG. 12 is a diagram showing a coil assembly mounting process;
FIG. 13 is a partially cutaway front view of a conventional coil device.
[Explanation of symbols]
(1) Iron core
(2) C-shaped split core piece
(3) Laminated core pieces
(4) Magnetic gap layer
(5) Coil assembly
(51) Bobbin
(52) Coil
(21) Wrapped iron core member
(31) Iron plate
(53) Bobbin
Claims (2)
前記ボビンBobbins (53)(53) には、前記1或いは複数の積層鉄心片The one or more laminated core pieces (( 33 )) がインサートモールドによって埋設され、該積層鉄心片Embedded in the insert mold, the laminated core piece (( 33 )) がボビンBobbin (53)(53) に保持された状態で一対のC字状分割鉄心片A pair of C-shaped split core pieces held in (( 22 )() ( 22 )) の切断面の間に介在すると共に、C字状分割鉄心片C-shaped split core pieces that are interposed between the cut surfaces of (( 22 )) と積層鉄心片And laminated core pieces (( 33 )) の対向面間並びに積層鉄心片Between facing surfaces and laminated core pieces (( 33 )) どうしの対向面間にボビンBobbin between the opposing faces (53)(53) の一部が介在して、前記磁気ギャップ層Part of the magnetic gap layer (( 44 )) を形成していることを特徴とするコイル装置。The coil apparatus characterized by forming.
金属製の帯板を巻回して環状の巻き鉄心部材An annular wound core member by winding a metal strip (21)(twenty one) を作製した後、該巻き鉄心部材After producing the wound iron core member (21)(twenty one) を分断して一対のC字状分割鉄心片A pair of C-shaped split core pieces (( 22 )() ( 22 )) を得る工程と、Obtaining
鉄板片Iron plate (31)(31) を積層してなる直方体状の積層鉄心片A rectangular parallelepiped laminated core piece formed by laminating (( 33 )) を1或いは複数個作製した後、インサートモールドによってボビン1 or more, and then bobbin with insert mold (53)(53) 中に前記1或いは複数個の積層鉄心片One or a plurality of laminated core pieces inside (( 33 )) を埋設すると共に、ボビンAnd burying the bobbin (53)(53) の一部によって前記磁気ギャップ層Part of said magnetic gap layer (( 44 )) を形成する工程と、Forming a step;
前記一対のC字状分割鉄心片The pair of C-shaped split core pieces (( 22 )() ( 22 )) の対向する切断面の間に、前記1或いは複数個の積層鉄心片1 or a plurality of laminated core pieces between the opposing cut surfaces (( 33 )) が埋設されたボビンBobbins embedded in (53)(53) を介在させることにより、前記鉄心By interposing the iron core (( 11 )) を組み立てる工程Assembling process
とを有していることを特徴とするコイル装置の製造方法。The manufacturing method of the coil apparatus characterized by having these.
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JP5087880B2 (en) * | 2006-08-04 | 2012-12-05 | 住友電気工業株式会社 | Reactor |
JP5310460B2 (en) * | 2009-10-09 | 2013-10-09 | Jfeスチール株式会社 | Manufacturing method of laminated core |
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