JP4906580B2 - Gapped transformer and method of manufacturing the same - Google Patents

Description

  The present invention relates to a transformer with a gap having a substantially C-shaped core partially formed with a gap, and a method of manufacturing the same.

  For a transformer with a gap having a substantially C-shaped core partially formed with a gap, for example, for the purpose of increasing the accuracy of the output of the secondary winding and suppressing the variation of the secondary winding output among the individual, Conventionally, for example, it is manufactured as follows. That is, the secondary winding is wound at substantially equal intervals from one end portion having a face facing the gap of the substantially C-shaped core partially formed with a gap to the other end portion having the face facing the gap. After that, the core and the secondary winding are covered with an insulating material, the secondary winding is fixed to the core, and a primary conductor is wound from above the insulating material at a position substantially opposite to the gap of the core (for example, Patent Document 1). reference).

JP 2006-310677 A

  However, in the conventional manufacturing method, the primary conductor is fixed to the insulating material with an adhesive. This fixing with the adhesive not only causes variations in the positioning of the primary conductor, but also takes time to dry the adhesive, so it is inefficient in terms of workability and productivity, and it takes a reasonable time and cost to manufacture. It was considered a problem.

  The present invention was made to solve the above-described problems, and can easily and accurately fix the primary conductor without the need for an adhesive, thereby improving workability and productivity. An object of the present invention is to obtain a transformer with a gap and a method for manufacturing the same.

In order to solve the above-described problems and achieve the object, a transformer with a gap according to the present invention includes a substantially C-shaped core in which a gap is formed in a part, and one end to the other end that form the gap of the core. The secondary winding wound at substantially equal intervals, the core and the secondary winding are accommodated, and through holes are formed on both side surfaces facing the central hole of the core, and the first is formed on the outer surface opposite to the gap. An insulating case provided with a bundling portion, and a primary conductor that is wound from above the insulating case at a position opposite to the gap through the insertion hole through the center hole of the core and bundled at the bundling portion. The insertion hole is a hole having the same shape as the cross-sectional shape of the primary conductor .

In the method for manufacturing a transformer with a gap according to the present invention, the secondary winding is wound at substantially equal intervals from one end portion to the other end portion of the substantially C-shaped core having a gap formed in a part thereof. After that, the core and the secondary winding are accommodated in the insulating case, and are formed in both sides facing the central hole of the core of the insulating case and inserted into the insertion hole which is a hole having the same shape as the cross-sectional shape of the primary conductor. Insert the conductor, wind the primary conductor around the core at the position opposite to the gap from above the insulating case, and then pass it through the bundling part provided on the outer surface opposite to the gap of the insulating case. It is characterized by bundling.

  According to the present invention, since the primary conductor is positioned and fixed by inserting the primary conductor through the insertion holes formed on both side surfaces facing the central hole of the core of the insulating case, an adhesive is required. Therefore, the primary conductor can be fixed easily and accurately, and workability and productivity can be improved.

  Embodiments of a gap transformer and a method for manufacturing the same according to the present invention will be described below in detail with reference to the drawings. The present invention is not limited to the embodiments.

Embodiment 1 FIG.
FIG. 1 is a perspective view of a gap transformer according to a first embodiment of the present invention. FIG. 2 is a perspective view of the core around which the secondary winding is wound. FIG. 3 is a side view of the insulating case. FIG. 4 is an enlarged view of arrow A in FIG. In the present embodiment, the upper, lower, left, and right sides of the apparatus will be described in the state shown in FIG. 1, but the direction of the apparatus is not limited to this.

  In FIG. 1, a substrate-mounted toroidal gap transformer 10 includes a substantially C-shaped core 11 with a gap G formed in part, a secondary winding 12 wound around the core 11, It has an insulating case 14 that houses the secondary winding 12, and a primary conductor 19 that is wound on the core 11 from above the insulating case 14.

  The core 11 is a toroidal type (doughnut-shaped (substantially C-shaped because there is a gap)) core and has a substantially C-shape, and a gap G is formed between opposite ends of the C-shape. Since the core 11 is substantially C-shaped, a central hole H is formed at the center of the C-shape. The secondary winding 12 is wound at substantially equal intervals from one end to the other end forming the gap G of the core 11 (FIG. 2).

  The insulating case 14 includes a case body 15 having a substantially rectangular box shape, and a first bundling portion 16 and a second bundling portion 17 protruding from the upper side surface of the case main body 15. The core 11 around which the secondary winding 12 is wound is housed in the case body 15 so that the gap G is positioned below. That is, the first bundling part 16 and the second bundling part 17 protrude from the side surface of the case body 15 on the side opposite to the gap G. The insulating case 14 is divided into two so as to be cut along a plane parallel to the paper surface of FIG. 1, for example, and the core 11 is accommodated therein. An output terminal 21 of the secondary winding 12 is erected on the lower surface of the case body 15. Further, on the lower surface of the case main body 15, mounting feet 23 are also provided as substrate fixing means.

  Insertion holes 15a through which the primary conductors 19 are inserted are respectively provided above the centers of both side surfaces facing the center hole H of the core 11 of the case body 15 by a predetermined distance. The insertion hole 15a has the same shape as the cross-sectional shape of the primary conductor 19 (FIG. 3). The primary conductor 19 passes through the two insertion holes 15 a provided on both side surfaces of the case body 15, thereby crossing directly under the core 11. The insertion hole 15a allows the primary conductor 19 to be inserted and restricts the movement of the primary conductor 19 at the hole position.

  The first bundling portion 16 and the second bundling portion 17 are formed in a substantially plate shape extending upward from both end portions of the upper side surface of the case main body 15 and have a rectangular hole 16a and a rectangular hole 17a through which the two primary conductors 19 are inserted. Are vacated. The rectangular holes 16 a and 17 a have a vertical height that is the same as the diameter of the primary conductor 19 and a horizontal width that is twice the diameter of the primary conductor 19. 4 shows the size of the rectangular hole 16a together with the cross section of the primary conductor 19, the rectangular hole 17a has the same shape. In other words, the rectangular holes 16a and 17a are sized to allow the two primary conductors 19 to be folded back to be inserted and restrict the movement of the primary conductors 19 in the vertical and horizontal directions. One of the first binding portion 16 and the second binding portion 17 is selected and used depending on the lead direction of the primary conductor 19.

  The primary conductor 19 is first inserted into the rectangular hole 16a from the direction of the arrow A in FIG. 1 and then passed through the two insertion holes 15a, folded back and inserted again into the rectangular hole 16a. On the other hand, a winding of one turn is formed. Then, the two primary conductors 19 that are folded back are twisted (twisted in a spiral) from a position that protrudes outward from the rectangular hole 16a. The primary conductor 19 is twisted to increase the cross section in the height direction and is restricted from moving inside the rectangular hole 16a. Thus, the primary conductor 19 is easily and reliably positioned so as to have a predetermined shape at a predetermined position by being further twisted by passing through the insertion hole 15a and the rectangular hole 16a.

  By storing the core 11 in the case body 15 so that the position of the gap G is the opposite position of the first binding portion 16 and the second binding portion 17, the position of the winding formed by the primary conductor 19 can be determined. The position can be opposite to the gap G. As described in detail in Patent Document 1, the accuracy of the secondary winding output is improved and the variation of the secondary winding output between individual transformers is suppressed by such an arrangement. This is a well-known technique.

  As described above, in the transformer according to the present embodiment, the primary conductor 19 is inserted into the insertion holes 15a formed on both side surfaces facing the central hole H of the core 11 of the insulating case 14 (case body 15). Since the primary conductor 19 is positioned and fixed, it is not necessary to use an adhesive, and the primary conductor 19 can be fixed easily and accurately even if a non-expert is working. In addition, workability and productivity can be significantly improved, and further cost reduction can be achieved.

  Further, in the transformer of the present embodiment, either one of the first binding portion 16 and the second binding portion 17 provided to face the outer surface opposite to the gap G of the insulating case 14 is selected. The primary conductor 19 is bundled. As a result, when the direction in which the primary conductor 19 is pulled out is changed, it is possible to respond quickly and increase the degree of freedom in arranging the transformer.

  Furthermore, the insulating case 14 of the present embodiment has mounting feet 23 as substrate fixing means that protrudes from the bottom surface and is fixed to a substrate (not shown). Therefore, the transformer can be easily mounted directly on the board using the mounting feet 23.

  In addition, the 1st binding part 16 and the 2nd binding part 17 of this Embodiment are formed in the general | schematic plate shape extended upward from the both ends of the upper surface of case main body 15, and the two primary conductors 19 are penetrated. Although the rectangular hole 16a and the rectangular hole 17a are respectively formed, the means for binding the two primary conductors 19 may not be a hole. For example, the two primary conductors 19 are arranged on the inside thereof. It may be a C-shaped part or the like that is inserted through the.

Embodiment 2. FIG.
FIG. 5 is a perspective view of a second embodiment of a transformer with a gap according to the present invention. FIG. 6 is a side view of the insulating case. In the first embodiment, the number of turns of the primary conductor 19 is one turn (one turn). However, in the present embodiment, the primary conductor 19 is wound twice (two turns) on the core 11. . Therefore, the insertion holes 15c formed on both side surfaces facing the central hole H of the core 11 of the insulating case 14A (case body 15) are sized to accommodate two primary conductors 19. Other configurations are the same as those of the first embodiment.

  In the present embodiment, the primary conductor 19 is wound twice (two turns) with respect to the core 11. However, the primary conductor 19 may be wound with n turns (n turns) based on the same idea. . That is, the insertion hole 15c is a hole having a size including n cross-sectional shapes of the primary conductor 19, and the primary conductor 19 is inserted into the insertion hole 15c from the top of the insulating case 14A to the core 11. You may wind.

  In the transformer having such a configuration, the primary conductor 19 is inserted a plurality of times through the insertion holes 15c formed on both side surfaces facing the central hole H of the core 11 of the insulating case 14A (case body 15). The primary conductor 19 can be wound a plurality of times, and the primary conductor 19 can be fixed easily and accurately without requiring an adhesive even in such a plurality of turns. And productivity can be improved.

Embodiment 3 FIG.
FIG. 7 is a perspective view of a third embodiment of a transformer with a gap according to the present invention. The insulating case 14B according to the present embodiment has a fixing screw insertion hole 15d screwed at substantially the center of the side surface of the case body 15 as a substrate fixing means that is fixed to a substrate (not shown). Other configurations are the same as those of the second embodiment.

  In the transformer having such a configuration, the transformer can be easily mounted directly on the device housing, for example, using the fixing screw insertion hole 15d.

  As described above, the transformer with a gap according to the present invention is useful for a small transformer optimal for use in a relay device or the like, and is particularly suitable for being applied to a small transformer mounted on a substrate.

It is a perspective view of Embodiment 1 of the transformer with a gap concerning the present invention. It is a perspective view of the core by which the secondary winding was wound. 3 is a side view of the insulating case of Embodiment 1. FIG. It is the arrow A enlarged view of FIG. 1 which shows the mode of the binding part of an insulation case. It is a perspective view of Embodiment 2 of the transformer with a gap concerning the present invention. 6 is a side view of an insulating case according to Embodiment 2. FIG. It is a perspective view of Embodiment 3 of the transformer with a gap concerning the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Transformer 11 The substantially C-shaped core in which the gap was formed 12 Secondary winding 14, 14A, 14B Insulating case 15 Case main body 15a, 15c Insertion hole 15d Fixing screw insertion hole 16 1st binding part 17 2nd binding part 16a , 17a Rectangular hole 19 Primary conductor 21 Output terminal 23 Mounting foot G Gap H Center hole of core

Claims (11)

A substantially C-shaped core with a gap formed in part;
A secondary winding wound at substantially equal intervals from one end to the other end forming the gap of the core;
The core and the secondary winding are accommodated, on both side surfaces facing the center hole of the core, a predetermined distance away from the center of the center hole, and at a position opposite to the gap with respect to the center of the center hole. An insulating case having an insertion hole and a first bundling portion provided on the outer surface opposite to the gap;
A primary conductor that passes through the central hole of the core, passes through the insertion hole, is wound around the core from above the insulating case at a position opposite to the gap, and is bundled at the first binding portion. ,
The gap transformer , wherein the insertion hole is a hole having the same shape as the cross-sectional shape of the primary conductor .   A substantially C-shaped core with a gap formed in part;
  A secondary winding wound at substantially equal intervals from one end to the other end forming the gap of the core;
  The core and the secondary winding are accommodated, on both side surfaces facing the center hole of the core, a predetermined distance away from the center of the center hole, and at a position opposite to the gap with respect to the center of the center hole. An insulating case having an insertion hole and a first bundling portion provided on the outer surface opposite to the gap;
  A primary conductor that passes through the central hole of the core, passes through the insertion hole, is wound around the core from above the insulating case at a position opposite to the gap, and is bundled in the first binding portion;
  With
  The insertion hole is a hole having a size including n cross-sectional shapes of the primary conductor,
  The primary conductor passes through the insertion hole and is wound n times around the core from above the insulating case.
  A transformer with a gap.   3. The gap transformer according to claim 1, wherein the first binding portion is a hole having a size including two cross-sectional shapes of the primary conductor. The transformer with a gap according to any one of claims 1 to 3, wherein the primary conductor is twisted at a position extending outward from the first bundling portion. 5. The second bundling portion is provided at a position facing the first bundling portion on the outer surface opposite to the gap of the insulating case. 5. Transformer with gap. The transformer with gap according to any one of claims 1 to 5, wherein the insulating case has a substrate fixing means. The gap transformer according to claim 6, wherein the board fixing means is a mounting foot provided on an outer surface of the insulating case. The gap transformer according to claim 6, wherein the board fixing means is a fixing screw insertion hole screwed into the insulating case. A secondary winding is wound at substantially equal intervals from one end portion to the other end portion of the substantially C-shaped core in which a gap is partially formed, and then the core and the secondary winding are Stored in an insulating case and formed on opposite sides of the central hole of the insulating case at a predetermined distance from the center of the central hole and on opposite sides of the gap with respect to the center of the central hole. it is, by inserting the primary conductor insertion hole is a cross-sectional shape and the hole of the same shape of the primary conductor, winding the primary conductor to the core on the opposite side of the position and the gap from the top of the insulating case, Furthermore, the said primary conductor is bundled by passing through the bundling part provided in the outer surface on the opposite side to the said gap of the said insulation case. The manufacturing method of the transformer with a gap characterized by the above-mentioned. The method of manufacturing a transformer with a gap according to claim 9, wherein the primary conductor is twisted after being pulled out from the binding portion. The primary conductor is bundled by selecting one of a first bundling portion and a second bundling portion provided to face an outer surface opposite to the gap of the insulating case. A method for manufacturing a transformer with a gap according to 9 or 10.

Images