JP4301248B2 - Electromagnetic device - Google Patents

Description

  The present invention relates to an electromagnetic device for generating a high-pressure pulse voltage, such as a starter for a high-pressure discharge lamp.

  FIG. 15 is a schematic diagram of a conventional electromagnetic device. The electromagnetic device shown in this figure is a pulse transformer used in a high voltage generator called an igniter to start a high pressure discharge lamp, and converts a low voltage into a high voltage. In the example of FIG. 15, the electromagnetic device stores a rod-shaped ferrite core 3PA, a bobbin 4PA, coil windings 1 and 2 wound around the side surface of the ferrite core 3PA using the bobbin 4PA, and these. A resin case 5PA and terminals 6 protruding from the case 5PA and connected to the coil windings are formed. The coil winding 1 is an insulation-coated electric wire (round wire) composed of a conductor wire having a circular cross section and an insulation coating covering the conductor wire, and is used as a primary winding, and the coil winding 2 is a secondary winding. Used as a line. A plurality of terminals 6 are provided, the terminal 6 (61) is connected to the coil winding 1, and the terminal 6 (62) is connected to the coil winding 2.

In this configuration, the coil windings 1 and 2 are wound around the bobbin 4PA, the ferrite core 3PA is inserted into the bobbin 4PA, these are incorporated into the case 5PA, and each coil winding is connected to each terminal 6, and the case It is produced by filling an epoxy resin in 5PA (epoxy vacuum filling). (For example, see Patent Document 1)
JP 2000-150266 A (paragraph numbers [0003] to [0005], FIGS. 5 and 6)

  However, the electromagnetic device manufacturing procedure of FIG. 15 requires a manufacturing tact of 4 hours or more including preliminary, drying, and curing, and there is a problem that the capital investment must be increased in the case of an increase in quantity. .

  Furthermore, in the case of epoxy vacuum filling, the direction in which each terminal 6 is taken out from the case 5PA is limited to one direction. Therefore, after filling with the epoxy resin, for example, each terminal 6 can be bent in the required direction to support various designs. I couldn't do something like that. In the case of the coil winding, metal springback occurs, so that it is necessary to entangle the end of the coil winding or to provide a temporary holding portion. In the case of epoxy filling, a boundary surface is formed between the case 5PA and the epoxy resin, and a high voltage may leak to the outside along the boundary surface. In the case of edgewise winding, if the curvature radius of the coil winding is small, the coating may be peeled off.

  The present invention has been made in view of the above circumstances, and an object thereof is to provide an electromagnetic device that is easy to manufacture.

In order to solve the above-mentioned problem, the invention according to claim 1 is directed to at least one ferrite core, at least two coil windings wound around the ferrite core, and externally connecting to the coil winding. An electromagnetic device having a transformer structure having at least two terminals, wherein the periphery of the transformer is sealed by injection molding of a thermosetting resin, and the periphery of the thermosetting resin is further molded by a thermoplastic resin, and then released. Used in an igniter part of an electric lamp lighting device , one of the two coil windings is a primary winding, the other is a secondary winding, and a fused wire is used for the primary winding. The primary winding is wound around the upper layer of the secondary winding, and then the primary winding is fused and fixed to the secondary winding by current conduction .

  According to a second aspect of the present invention, in the electromagnetic device according to the first aspect of the present invention, the electromagnetic device further includes a lead frame that holds a molded content during the injection molding.

According to a third aspect of the invention, wherein an electromagnetic device according to claim 1, wherein that the pre-Symbol round wire in the primary winding is used, said secondary winding being used flat wire And

According to a fourth aspect of the present invention, in the electromagnetic device according to any one of the first to third aspects, an end of at least one of the two coil windings is fixed with an adhesive. It is characterized by that .

According to a fifth aspect of the present invention, in the electromagnetic device according to any one of the first to fourth aspects, the secondary winding is formed by coating a rectangular wire wound in an edgewise manner. .

As apparent from the above, the invention according to claim 1 is connected to at least one ferrite core, at least two coil windings wound around the ferrite core, and the coil windings from the outside. An electromagnetic device having a transformer configuration having at least two terminals for sealing, wherein the periphery of the transformer is sealed by injection molding of a thermosetting resin, and the periphery of the thermosetting resin is further molded by a thermoplastic resin Used in the igniter portion of the discharge lamp lighting device , one of the two coil windings is a primary winding, the other is a secondary winding, and the primary winding has a fusion wire. Used, the primary winding is wound on the upper layer of the secondary winding, and then the primary winding is fused and fixed to the secondary winding by energizing the current. Effective for securing and dampproofing Also, the primary winding can be easily fixed.

  According to the second aspect of the present invention, the electromagnetic device according to the first aspect has a lead frame for holding the molded contents at the time of the injection molding.

According to the third aspect of the present invention, the electromagnetic device according to claim 1 or 2, is used round wire before Symbol primary winding, said secondary winding since the rectangular wire is used It becomes possible to reduce the size.

According to a fourth aspect of the present invention, in the electromagnetic device according to any one of the first to third aspects, an end of at least one of the two coil windings is fixed with an adhesive. As a result, the coil winding is not unraveled by the springback .

According to a fifth aspect of the present invention, in the electromagnetic device according to any one of the first to fourth aspects, the secondary winding is formed by coating a rectangular wire wound in an edgewise manner. Can be realized.

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

(First Reference Example)
FIG. 13 is a configuration diagram of an electromagnetic device, and a first reference example of the present invention will be described with reference to these drawings.

The electromagnetic device shown in FIG. 13 is a rod-shaped rod-shaped ferrite core 3 having a specific resistance of 10 ³ Ωm or more, and a flat wire is formed on one side of the ferrite core 3 without using a bobbin as an insulating member. A coil winding 2 formed by edgewise winding, an insulation-coated electric wire whose core wire is covered with an insulation coating, a coil winding 1 wound around an upper layer of the coil winding 2, and a resin-made housing for housing them The case 5 is composed of a plurality of terminals 6 protruding from the case 5 and connected to the coil windings.

  In this configuration, since the coil windings 1 and 2 are directly wound around the side surface of the ferrite core 3 without passing through the bobbin, each terminal 6 cannot be fixed to the bobbin. Therefore, in the first reference example, as shown in FIG. 13C, a hoop material 60 having the terminals 6 integrally is used. In this case, the end of the corresponding coil winding is joined to each terminal 6 of the hoop material 60. Here, as shown in FIG. 13A, by pulling out all the terminals 6 in the same direction, the hoop material 60 can be formed in a simple shape, and as shown in FIG. Even when the case 5 for electrical insulation or the like is formed by molding, since the terminals 6 are arranged in a line, the joining in the next process becomes easy.

  Further, in the first reference example, in order to wind the coil winding 2 directly on the side surface of the ferrite core 3, holes 31 having bottom portions are formed on both end surfaces of the ferrite core 3, and these holes 31 are formed by winding It is used for positioning in the axial direction of the rotation.

(Second reference example)
FIG. 14 is a diagram showing a ferrite core in an electromagnetic device, and a second reference example of the present invention will be described with reference to this figure.

  As shown in FIG. 14, the electromagnetic device includes a ferrite core 3A having holes 31 similar to those in the first reference example on both end surfaces and having an elliptical cross-sectional shape. The electromagnetic device is configured in the same manner as the first reference example except that it is provided in place of the core 3.

  By using such a flat ferrite core 3A, a thin electromagnetic device having a transformer structure can be manufactured.

(First embodiment)
1 is a perspective view and a partial cross-sectional view showing the electromagnetic device, FIG. 2 is a plan view of the electromagnetic device in FIG. 1, and FIG. 3 is an electromagnetic device in FIG. 2 from the electromagnetic device being manufactured before the electromagnetic device in FIG. FIG. 4 is a schematic diagram showing an electromagnetic device being manufactured, FIG. 5 is a plan view of the electromagnetic device in FIG. 4, and FIG. 6 is for manufacturing the electromagnetic device in FIG. 4. FIG. 7 is a diagram showing a ferrite core and a plurality of coil windings used, FIG. 7 is a schematic diagram showing an electromagnetic device being manufactured before FIG. 4, and FIG. 8 is a plan view of the electromagnetic device in FIG. A first embodiment of the present invention will be described with reference to FIG.

  First, the manufacturing procedure until the electromagnetic device in the middle of manufacture shown in FIGS. 4 and 5 is obtained will be described. First, as shown in FIG. 6, the first intermediate is obtained by winding the coil windings 1 and 2 around the side surface of the ferrite core 3 </ b> A formed in an elliptical cross-sectional shape without using an insulating member. At this time, the rectangular coil winding 2 is directly wound around the side surface of the ferrite core 3 </ b> A in an edgewise manner, and the coil winding 1 is wound around a predetermined region above the coil winding 2.

  Thereafter, as shown in FIGS. 7 and 8, each end of the coil windings 1 and 2 in the first intermediate is connected to the corresponding terminal 6 of the lead frame 60A which is a continuous and integral metal piece. Two intermediates are obtained. Thereafter, the second intermediate is set in a not-shown mold, and the inside of the mold containing all of the first intermediate is sealed with a thermosetting resin such as unsaturated polyester (injection molding), A third intermediate part is obtained in which the insert molding member 5B shown in FIGS. 4 and 5 is formed on the lead frame 60A.

  In this manufacturing procedure, the conventional vacuum filling tact of 4 hours or more can be shortened to about 2 minutes by the injection molding. Further, the case can be reduced in size by the caseless outer frame.

  Then, after the above-described third intermediate part is obtained, the coil winding 1 in a state where each end of the coil windings 1 and 2 is connected and fixed to each terminal 6 as a part of the lead frame 60A. , 2 so that the electrical connection by the lead frame 60A is cut off. Thereby, the 4th intermediate part shown in Drawing 3 (a) is obtained. After that, as shown in FIG. 3B, the terminals 6 are bent in a predetermined direction (arbitrary direction can be set) to obtain the electromagnetic device shown in FIGS.

  Here, as can be seen from FIG. 8A, in FIG. 1A, the terminal 6 (2R) to which the high voltage end 2R of the coil winding 2 is connected and both ends 1L, 1R of the coil winding 1 are connected. Are connected to one side of the insert molding member 5B from which the terminals 6 (1L) and 6 (1R) are connected, respectively, between the terminals 6 (2R) and the terminals 6 (1L) and 6 (1R). A plurality of grooves 51B are provided. Since the unevenness is thereby formed, the creeping distance of the insert molding member 5B between them can be increased, so that the insulation function can be enhanced and leakage between them can be prevented. The one side surface is not limited to a plurality of grooves, and may be a plurality of protrusions. Moreover, 50B shown in FIG.1 (b) shows the filler which comprises the insert molding member 5B.

  By the way, as shown in the example of FIG. 9, the electromagnetic device obtained by the above manufacturing procedure is used for a discharge lamp lighting device that supplies power to a discharge lamp La as a vehicle headlamp and maintains a lighting state. The As shown in the example of FIG. 10, this type of discharge lamp lighting device is provided with a starting circuit unit (igniter) IG that applies a high-voltage pulse voltage to the discharge lamp La when it is started. This electromagnetic device is provided in the dotted line region R2 of the activation circuit portion IG shown in FIG. 10, and the periphery of the thermosetting resin insert molding member 5B is frame-molded (double-molded) with a thermoplastic resin. . That is, the electromagnetic device is covered with the thermoplastic resin with each terminal 6 exposed to the outside. In the case of this double-molded structure, since almost the entire electromagnetic device is sealed with a thermoplastic resin, the interface becomes only each terminal, which is effective for securing an insulation distance and moisture-proofing. Further, since a plurality of grooves 51B extending from one edge to the other edge are provided on one side surface of the insert molding member 5B, each groove 51B is compulsory when molding a thermoplastic tree. Since it plays the role of the flow path, the fluidity of the melt-molded material can be improved.

(Second Embodiment)
FIG. 11 is a diagram showing a ferrite core and a plurality of coil windings in an electromagnetic device, and a second embodiment of the present invention will be described with reference to this figure.

  The electromagnetic device of the second embodiment is configured in substantially the same manner as the electromagnetic device of the first reference example, except that a coil winding 1B that is a fused wire is used instead of the coil winding 1 that is an insulation-coated electric wire. . The manufacturing procedure in the case of this configuration will be described. First, the coil winding 2 is provided on the side surface of the ferrite core 3 by winding a rectangular wire edgewise. Thereafter, a UV curable adhesive is applied to the regions R3 and R4 shown in FIG. 11 and cured by UV irradiation. Subsequently, a fusion wire is wound around a predetermined region on the upper layer of the coil winding 2 to provide the coil winding 1B, and then the coating of the coil winding 1B is fusion-fixed to the coil winding 2 by current conduction. . In this configuration, manufacture is facilitated, and both ends of the coil winding 2 are fixed to the side surfaces of the ferrite core 3 with an adhesive, so that the coil winding 2 is not unwound by springback.

(Third embodiment)
FIG. 12 is a diagram showing a ferrite core and a coil winding in an electromagnetic device, and a third embodiment of the present invention will be described with reference to this drawing.

  The electromagnetic device of the third embodiment is configured in substantially the same manner as the electromagnetic device of the first reference example, except that the entire coil winding 2 excluding both ends is covered with the thin film coating C. If the diameter of the ferrite core is reduced for miniaturization, when the coil winding 2 is provided by winding the flat wire on the side surface of the ferrite core 3 in an edgewise manner, the coating is avoided to avoid the coating because the curvature radius is small. Rare shorts can occur between windings. For this reason, in the third embodiment, the coil winding 2 is covered with the thin film coating C after the coil core 2 is provided on the side surface of the ferrite core 3 by edgewise winding the rectangular wire. Thereby, generation | occurrence | production of the rare short circuit between the windings of the coil winding 2 can be prevented.

It is the perspective view and partial sectional view which show an electromagnetic device. It is a top view of the electromagnetic device of FIG. It is explanatory drawing of the manufacturing procedure for obtaining the electromagnetic device of FIG. 2 from the electromagnetic device in the middle of manufacture before the electromagnetic device of FIG. 2 is obtained. It is the schematic which shows the electromagnetic device in the middle of manufacture. It is a top view of the electromagnetic device of FIG. It is a figure which shows the ferrite core and several coil windings which are used for manufacture of the electromagnetic device of FIG. It is the schematic which shows the electromagnetic device in the middle of manufacture before FIG. It is a top view of the electromagnetic device of FIG. It is a figure which shows the example of the discharge lamp lighting device comprised using an electromagnetic device. It is a figure which shows the example of the starting circuit part with which the discharge lamp lighting device of FIG. 9 is equipped. It is a figure which shows the ferrite core and several coil winding | winding in an electromagnetic device. It is a figure which shows the ferrite core and coil winding in an electromagnetic device. It is a block diagram of the electromagnetic device of a reference example. It is a figure which shows the ferrite core in the electromagnetic device of a reference example. It is a schematic diagram of the conventional electromagnetic device.

Explanation of symbols

1 Coil Winding 2 Coil Winding 3 Ferrite Core 5B Insert Molding Member 6 Terminal

Claims (5)

An electromagnetic device having a transformer configuration having at least one ferrite core, at least two coil windings wound around the ferrite core, and at least two terminals for connecting to the coil winding from the outside. ,
The periphery of the transformer is sealed by injection molding of a thermosetting resin, the periphery of the thermosetting resin is further molded by a thermoplastic resin, and used for an igniter portion of a discharge lamp lighting device ,
One of the two coil windings is a primary winding, and the other is a secondary winding. A fused wire is used for the primary winding, and a primary winding is formed on the upper layer of the secondary winding. An electromagnetic device characterized in that after winding a winding, the primary winding is fused and fixed to the secondary winding by energizing current . The electromagnetic device according to claim 1, further comprising a lead frame that holds a molding content during the injection molding. Before Symbol primary winding is used round wire, the electromagnetic device according to claim 1, wherein said secondary winding, characterized in that the flat wire is used. The electromagnetic device according to any one of claims 1 to 3, wherein an end portion of at least one of the two coil windings is fixed with an adhesive. The electromagnetic device according to claim 1, wherein the secondary winding is formed by coating a rectangular wire wound in an edgewise manner.

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