JP3671171B2 - Coil device and manufacturing method thereof - Google Patents

Description

[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)

An annular wound core member made by winding a metal strip (twenty one) A pair of C-shaped split core pieces separated from each other ( 2 ) ( 2 ) And the pair of C-shaped split core pieces ( 2 ) ( 2 ) One or a plurality of rectangular parallelepiped laminated core pieces interposed between the cut surfaces of ( 3 ) And C-shaped split core piece ( 2 ) And laminated core pieces ( 3 ) Between facing surfaces and laminated core pieces ( 3 ) Magnetic gap layer between two opposing surfaces ( 4 ) And, by the annular iron core ( 1 ) And the iron core ( 1 ) Surrounding the magnetic path formed by the bobbin (53) Coil around (52) Coil assembly formed by winding (57) In the coil device to which
Bobbins (53) The one or more laminated core pieces ( 3 ) Embedded in the insert mold, the laminated core piece ( 3 ) Bobbin (53) A pair of C-shaped split core pieces held in ( 2 ) ( 2 ) C-shaped split core pieces that are interposed between the cut surfaces of ( 2 ) And laminated core pieces ( 3 ) Between facing surfaces and laminated core pieces ( 3 ) Bobbin between the opposing faces (53) Part of the magnetic gap layer ( 4 ) The coil apparatus characterized by forming. An annular wound core member made by winding a metal strip (twenty one) A pair of C-shaped split core pieces separated from each other ( 2 ) ( 2 ) And the pair of C-shaped split core pieces ( 2 ) ( 2 ) One or a plurality of rectangular parallelepiped laminated core pieces interposed between the cut surfaces of ( 3 ) And C-shaped split core piece ( 2 ) And laminated core pieces ( 3 ) Between facing surfaces and laminated core pieces ( 3 ) Magnetic gap layer between two opposing surfaces ( 4 ) And, by the annular iron core ( 1 ) And the iron core ( 1 ) Surrounding the magnetic path formed by the bobbin (53) Coil around (52) Coil assembly formed by winding (57) In the manufacturing method of the coil device to which is attached,
An annular wound core member by winding a metal strip (twenty one) After producing the wound iron core member (twenty one) A pair of C-shaped split core pieces ( 2 ) ( 2 ) Obtaining
Iron plate (31) A rectangular parallelepiped laminated core piece formed by laminating ( 3 ) 1 or more, and then bobbin with insert mold (53) One or a plurality of laminated core pieces inside ( 3 ) And burying the bobbin (53) Part of said magnetic gap layer ( 4 ) Forming a step;
The pair of C-shaped split core pieces ( 2 ) ( 2 ) 1 or a plurality of laminated core pieces between the opposing cut surfaces ( 3 ) Bobbins embedded in (53) By interposing the iron core ( 1 ) Assembling process
The manufacturing method of the coil apparatus characterized by having these.

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