JP5219151B2 - Trance - Google Patents

Description

  The present invention relates to a transformer having a structure in which a lead terminal of a coil can be formed and held so that a terminal at a tip can be aligned with a mounting position of a substrate, and more specifically, along a wiring path of a lead line. A wiring support portion extending outward is formed integrally with the insulating cover, and the lead wire is formed by fixing the lead wire with a wiring fixture on the wiring support portion, thereby defining the position of the terminal at the tip. It is related to the transformer. This technique is useful, for example, for a transformer of an in-vehicle DC-DC converter.

  In the main transformer for voltage conversion incorporated in the DC-DC converter for automobiles, a large current flows on the secondary side of the low voltage, so a ring opened by punching a thick copper plate into the secondary coil by pressing or the like A one-turn conductor having a shape is used, whereas the primary coil is configured to wind an insulation-coated electric wire around a bobbin a plurality of times. Specifically, for example, a primary coil in which an insulation-coated electric wire is wound around a bobbin, a first insulating cover that accommodates the primary coil, a secondary coil made of a punched copper plate, and the secondary coil are accommodated. A magnetic path that passes through the inside and outside of both coils is formed by assembling a magnetic core from the outside of the first and second insulating covers in a state where the primary coil and the secondary coil are overlapped. Structure. Here, the first and second insulating covers and the bobbin are both synthetic resin molded products, the first insulating cover ensures electrical insulation between the primary coil and the magnetic core, and the second insulating cover is The electrical insulation between the secondary coil and the magnetic core is ensured, and the bobbin functions to ensure electrical insulation between the primary coil and the secondary coil.

  The transformer having such a structure is mounted on a converter board or the like. Since the secondary coil is made of a punched copper plate, the coil itself is thick and has shape retaining properties. By forming a mounting hole at the tip and forming the mounting hole into a desired shape so that it can be guided to the mounting location of the substrate, It can be easily connected to an external circuit by screwing. On the other hand, the lead wire of the primary coil is flexible because it is an extended portion of the winding, and is drawn long so as to reach the attachment location. Therefore, in general, in order to ensure electrical insulation, a method has been adopted in which an insulating tube is placed on the lead wire to prevent interference with other mounting parts and the crimp terminal at the tip is routed to the mounting location. In addition, there is a method (see Patent Document 1) in which wiring is performed by extending to an attachment location using a harness component or the like.

  In any case, the harness parts and the lead wires are relatively flexible so that they can be routed freely. Therefore, the installation operator guides the crimp terminals individually to the mounting location on the board and aligns them each time. There is a drawback that connection work such as screwing has to be performed, which requires man-hours and makes the installation work cumbersome. In addition, when harness parts are used, the parts cost increases accordingly, and there is also a problem that the work becomes complicated when covering with an insulating tube.

JP 2001-85240 A

  The problem to be solved by the present invention is that no separate parts are required for installation, and that the terminals are inevitably guided to the installation location so that the alignment man-hours are not taken, so that the installation work is facilitated. It is possible to reduce the man-hours and the number of parts.

The present invention includes a primary coil in which an insulation-coated electric wire is wound around a bobbin, a first insulating cover that accommodates the primary coil, a secondary coil made of a punched plate-shaped conductive material, and the secondary coil A magnetic path that includes a second insulating cover that accommodates the coil, and passes through the inside and outside of both coils by assembling a magnetic core from the outside of the first and second insulating covers in a state where the primary coil and the secondary coil are overlapped. In the transformer having a structure, the first insulating cover includes a cover main body that houses the primary coil, and a wiring support that extends outward from the cover main body along the wiring path of the lead wire of the primary coil. The wiring support part has a bowl shape with both side walls, and a wiring fixing tool for fixing the lead wire placed on the wiring support part is provided on the wiring support part. And then withdraw Line is trans, characterized in that is forming the tip of the pin was to be guided to the mounting position.

  The primary coil, for example, has two winding parts in which insulation-coated wires are wound around bobbins of the same shape, stacked so that they face each other, and each lead wire on the winding start side is placed between the overlapped bobbins. A structure that can be pulled out. In this way, a center tap type primary winding structure can be easily obtained. In this case, when the bobbin has a structure including a cylindrical winding body, flanges located on both sides thereof, and a large number of ribs disposed asymmetrically on the outer surface of one flange, the ribs face each other. If combined in the orientation, the overall height can be reduced by the height of one rib.

  Note that the end of the winding end of the insulated wire wound on one bobbin and the terminal of the leading end of the winding start side of the insulated wire wound on the other bobbin are stacked on the tip of the wiring support section. By attaching to the provided terminal fixing guide, both overlapping terminals are held at the same position, and can be connected and fixed with a single screw. Here, the terminal fixing guide is a groove portion that can be inserted in a state where two crimp terminals are overlapped, and forward and upward stoppers for constraining the position of the crimp portion are formed in the groove portion. The shape is preferable.

  For example, the wiring fixture is a plurality of wiring hooks arranged along the wiring path of the lead line on the wiring support part, and the lead line is formed by hooking the lead line to the wiring hook. To do. As a result, the crimp terminal at the tip can be guided to a predetermined mounting location such as a substrate.

  The first insulating cover that accommodates the primary coil preferably has a structure in which not only the cover body and the wiring support part but also the terminal fixing guide, the wiring hook, etc. are all integrally formed of synthetic resin.

  In the transformer according to the present invention, the first insulating cover that accommodates the primary coil includes a cover body and a wiring support portion that extends outward from the cover body along the wiring path of the primary coil lead wire. It is an integrated structure, and a wiring fixture is provided on the wiring support portion to hold the placed lead wire while forming, and the terminal at the tip of the lead wire is automatically guided to a predetermined mounting location. Therefore, sufficient insulation can be ensured by adding a wiring support part to the cover body without requiring separate parts such as a harness part and an insulating tube. Therefore, the number of parts does not increase, which contributes to material cost reduction. In addition, since the position of the terminal always matches the desired mounting location, troublesome alignment is not required during the mounting operation, and the number of mounting steps can be reduced and the operation can be made efficient.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an external explanatory view showing an embodiment of a transformer according to the present invention. Explanatory drawing of the coil | winding components used for a primary coil. Explanatory drawing of the bobbin used for winding components. Explanatory drawing of a primary coil. Explanatory drawing of a 1st insulating cover. The top view of a secondary coil. Explanatory drawing of a 2nd insulation cover. Explanatory drawing of the ferrite core which comprises a magnetic core.

  In the present invention, a wiring support portion extending outwardly along the wiring path of the lead wire of the primary coil from the cover main body that houses the primary coil is continuously provided, and the forming of the lead wire and the terminal at the tip are used by using the wiring support portion. Is configured to guide to a predetermined mounting location, thereby making it possible to easily perform the mounting operation without taking the man-hours for positioning the terminals.

  FIG. 1 shows the external shape of an embodiment of a transformer according to the present invention. Here, (a) represents a plane, (b) represents a front surface, and (c) represents a side surface. Moreover, (d) is the AA cross section of (a). The transformer includes a primary coil 10 and a secondary coil 12, and a magnetic core 14 that is assembled from the outside in a state where the primary coil 10 and the secondary coil 12 are overlapped to form a magnetic path that passes through the inside and outside of both coils. It has.

  The configuration of the primary coil will be described with reference to FIGS. As shown in FIG. 2, the primary coil has two winding parts 20 in which an insulated wire 18 is wound around a bobbin 16 having the same shape, and one of them is inverted as indicated by an arrow F so that they face each other. And overlapping (see FIG. 4).

  As shown in FIG. 3, the bobbin 16 is provided with flanges 24 a and 24 b on both sides of a cylindrical winding body 22, and a synthetic resin in which a large number of ribs 26 are circumferentially formed on one outer surface of the flange 24 a. It is a one-piece molded product. Each rib 26 is disposed asymmetrically with respect to the center line GG. The flange 24a is formed with a notch 28 for taking the insulated coated wire from the outside into the winding drum portion 22. Here, the interval between the flanges is set to be slightly larger than the diameter of the insulated coated wire to be wound, and the height of each rib 26 is set to be slightly higher than the diameter of the insulated coated wire.

  As shown in FIG. 2, the lead wire on the winding start side of the insulated wire 18 is set on the rib side of the bobbin 16, guided from the notch 28 to the winding body 22 and wound as many times as necessary to complete the winding. Drawn from between. A portion pulled out from the bobbin 16 is a lead wire 18a, which is set to a necessary length in consideration of an external attachment location, and a crimp terminal 28 is attached to the tip. Two winding components 20 each having the insulated wire 18 wound around the bobbin 16 are overlapped so that the ribs face each other to form the primary coil 10 (see FIGS. 2 and 4). At this time, the ribs 26 of both the winding components 20 are formed asymmetrically with respect to the center line GG. Therefore, when they are overlapped, the rib positions are shifted from each other. Only the overall height can be reduced and the combined state becomes stable. Moreover, the mold cost can be halved by making the two bobbins 16 into the same shape. In addition, although both winding components differ in the length of a leader line according to the attachment location of a terminal differing, the structure other than that may be completely the same.

  In this manner, by combining the two winding components 20, a total of four lead lines are drawn. Two draw-out lines on the winding start side are drawn out from between the combined bobbins in the left and right directions (symmetrical with respect to the bobbin center line GG: left and right in FIG. 3A). The draw-out line on the winding end side of the bobbin is drawn separately from the left and right sides between the flanges of each bobbin. Accordingly, each of the two lead wires on the left and right is a combination of the winding start side of one winding component and the winding end side of the other winding component. Therefore, the lead wire on the winding end side of one winding component and the lead wire on the winding start side of the other winding component are drawn from substantially the same position, and by making them the same length, both lead wires Center tap type connection can be realized by matching the position of the crimp terminal at the tip and screwing it together at the mounting location.

  Such a primary coil 10 is accommodated in the first insulating cover. This first insulating cover is shown in FIG. The first insulating cover 30 is a synthetic resin product in which a cover main body 32 that accommodates the primary coil 10 and a wiring support portion 34 that protrudes from one side to extend outward along the wiring path are integrally formed. is there. The cover body 32 has a ring shape and covers the outer peripheral surface of the primary coil. The wiring support part 34 is a part that holds the lead line placed thereon while forming it. Here, the wiring support part 34 protrudes in two directions. One is a first support part 34a for forming two lead lines on the center tap side, and the other is a second support part 34b for forming the remaining two lead lines.

  The first support portion 34a on the side of the center tap has a hook shape that can guide the two lead wires in a superimposed manner, and is provided with a terminal fixing guide 36 for inserting and attaching both the crimp terminals on the tip. (Refer to FIG. 1 (e)). With such a terminal fixing guide 36, the positions of the two crimp terminals 28 can be easily fixed. Here, the terminal fixing guide 36 has a groove structure that can be inserted in a state in which the two crimp terminals 28 are overlapped, and a forward stopper 38 and an upper stopper for restraining the position of the crimp portion in the groove portion. 40 is formed (see (f) of FIG. 1). The front stopper 38 is fitted in a constricted portion between the crimping terminal mounting hole portion and the crimping portion to regulate the horizontal position, and the upper stopper 40 is located on both upper sides of the crimping portion. The movement in the vertical direction is restricted, and thereby the accuracy of the fixing position of the crimp terminal 28 can be further enhanced.

  The second support portion 34b also has a bowl shape with both wall portions, and guides the remaining two lead lines in parallel. Here, in order to guide one lead line from the middle through another wiring route. Further, it has a shape that extends. In this embodiment, a wiring hook 42 is used as a wiring fixing tool, and a plurality of wiring hooks 42 are appropriately disposed in the vicinity of the crimping terminal and other intermediate positions for both lead wires. Each lead wire 18a is hooked on the wiring hook 42 to form, and the crimp terminal 28 at each tip is guided to a predetermined mounting location (see FIG. 1A).

  The terminal fixing guide and the wiring hook are formed integrally with the cover body and the wiring support part. When fixing two crimp terminals in the same position, the terminal fixing guide with a groove structure is preferable because the fixing position accuracy increases and it is difficult to shift each other. When fixing a single crimp terminal, The use of a wiring hook or the like is relatively simple and simple. In addition, the wiring support part also has an effect of suppressing variation in the magnetic characteristics of the transformer for each product by forming the lead line.

  As shown in FIG. 6, the secondary coil 12 is a one-turn coil conductor obtained by punching a thick copper plate by press working. In a plan view, the ring shape is open, and both end portions of the ring portion extend in parallel to the outside, and a mounting hole is formed at the tip. As shown in FIG. 7, the second insulating cover 44 has an inner ring wall 44b slightly higher than the thickness of the secondary coil 12 on one side of the cover plate 44a so that the ring-shaped portion of the secondary coil is just inserted. And an outer peripheral wall 44c projecting in the same direction. The secondary coil 12 is accommodated in the second insulating cover 44.

  When the primary coil 10 accommodated in the first insulating cover 30 and the secondary coil 12 accommodated in the second insulating cover 44 are overlapped, the primary coil 10 and the secondary coil 12 are electrically insulated by the bobbin. The Furthermore, a magnetic path is formed by assembling a magnetic core from the outside. As shown in FIG. 8, the magnetic core 14 has a structure in which two deformed E-type ferrite cores 46 each having a ring-shaped recess are combined so as to face each other. Two ferrite cores 46 are assembled from the outside of the first insulating cover 30 and the second insulating cover 44, a magnetic path passing through the inside and outside of both coils is formed, and the magnetic core 14 is fixed by winding an insulating tape 48. . In this way, a transformer is obtained. The first insulating cover 30 secures electrical insulation between the primary coil 10 and the magnetic core 14, and the second insulating cover 44 functions to secure electrical insulation between the secondary coil 12 and the magnetic core 14. Plays. In addition, the empty space formed in accordance with the shape of the wiring support portion (portions indicated by symbols D and E in FIG. 1A) can be used as a mounting space for the substrate. Since the wiring support portions 34a and 34b have a bowl shape with both wall portions and the electrical insulation of the lead wire is secured, other electronic components can be mounted using the mounting space. It can also contribute to downsizing.

  Mounting the magnetic core portion of the transformer on a substrate or the like and screwing each crimp terminal to a predetermined mounting location completes the incorporation into the external circuit. At that time, as described repeatedly, each crimp terminal is positioned on the mounting location without adjustment, so that the operator can easily perform the connection work.

  As can be seen from the above description, in the present invention, the shape of the first insulating cover installed in order to ensure electrical insulation between the primary coil and the magnetic core is devised, and the lead wire is placed to form the first insulating cover. By adding the wiring support part to be performed, it is possible to solve the problems of the prior art without increasing the number of parts, and to contribute to the reduction of the mounting man-hours. In the above embodiment, a primary coil is formed by combining two bobbins. However, the present invention can also be applied to a primary coil having a structure in which an insulated wire is wound around a single bobbin. Needless to say. The extending shape of the wiring support part is appropriately changed according to the required wiring path. The lead wire may be fixed only by the wiring hook, or the wiring hook and the terminal fixing guide may be used in combination as in this embodiment. The wiring fixing tool is not limited to the wiring hook, and may be a structure in which, for example, a lead wire is interposed and fixed. Note that the cover main body and the wiring support portion in the first insulating cover only have to be finally integrated, and a system in which the cover main body and the wiring support portion are separately molded and bonded by bonding or the like is also possible.

DESCRIPTION OF SYMBOLS 10 Primary coil 12 Secondary coil 14 Magnetic core 18 Insulated coated electric wire 18a Lead wire 28 Crimp terminal 30 First insulating cover 32 Cover main body 34 Wiring support part 36 Terminal fixing guide 38 Forward stopper 40 Upward stopper 42 Wiring Hook 44 Second insulation cover 48 Ferrite core

Claims (5)

A primary coil in which an insulation-coated electric wire is wound around a bobbin, a first insulating cover that accommodates the primary coil, a secondary coil made of a punched plate-shaped conductive material, and the secondary coil are accommodated A magnetic path passing through the inside and outside of both coils is formed by assembling a magnetic core from the outside of the first and second insulating covers with the second insulating cover and the primary coil and the secondary coil being overlapped. In the structure transformer,
The first insulating cover has a structure in which a cover main body that accommodates the primary coil and a wiring support portion that extends outward from the cover main body along the wiring path of the lead wire of the primary coil are integrated. The wiring support part has a bowl shape with both side walls, and a wiring fixing tool for fixing the drawn wire placed on the wiring support part is provided, whereby the lead line is formed. The transformer is characterized in that the tip terminal is guided to the mounting location.   The primary coil is composed of two winding parts with insulation-coated wires wound around the same shape bobbin so that they face each other, and the lead wire on the winding start side is drawn out from between the overlapped bobbins. The transformer according to claim 1, wherein the transformer has a possible structure.   It is provided at the tip of the wiring support section by overlapping the winding end side of the insulated coated wire wound on one bobbin and the terminal of the leading end of the winding start side of the insulated coated wire wound on the other bobbin. 3. The transformer according to claim 2, wherein both of the overlapping terminals are held at the same position by being mounted on the terminal fixing guide.   The terminal fixing guide is a groove portion that can be inserted in a state where two crimp terminals are overlapped, and forward and upward stoppers for restricting the position of the crimp portion are formed in the groove portion. The described transformer.   The wiring fixture is a plurality of wiring hooks arranged along the wiring path of the lead wire on the wiring support portion, and the lead wire is formed by hooking the lead wire to the wiring hook. The transformer according to any one of 1 to 4.

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