JP5390345B2 - Inductor - Google Patents

Description

  The present invention relates to an inductor formed by housing a core around which a conducting wire is wound in a case.

  As a reactor used in an electric circuit, an inductor as shown in Patent Document 1 is used. FIG. 7 shows a perspective view of an inductor (reactor) having a conventional configuration disclosed in Patent Document 1. In FIG.

JP 2009-26952 A

  As shown in FIG. 7, in the reactor 101 having the conventional configuration, a substantially O-shaped core 120 and a pair of windings that are wound around the core 120 are formed in a recess 111 a formed on the bottom surface 111 of the case 110. The line 130 is accommodated.

  In order to hold the core 120 in the recess 111 a of the case 110, four sets of fixing metal fittings 141 are used. Each of these fixing fittings 141 is a fitting integrated with the core 120 by a mold resin. The distal ends of the four sets of fixing fittings extend radially from the four corners of the core 120, respectively. A through hole (not shown) is formed at the distal end of the fixing metal 141. The core 120 attaches the fixing metal 141 to the case 110 by screwing the fixing metal 141 through the bolt 142 through the through hole of the fixing metal 141. And is fixed in the recess 111 a of the case 110.

  The fixing metal 141 floats the core 120 from the recess 111 a of the case 110 so that the core 120 does not contact the case 110. Thereby, direct contact between the case 110 and the core 120 is prevented. In the configuration of Patent Document 1, since the direct contact between the case 110 and the core 120 is prevented as described above, the vibration of the core 120 that can be generated when a current is passed through the winding is transmitted to the case 110. And noise generation due to vibration of the case 110 is prevented.

  In the configuration in which the core 120 and the fixture 141 are integrated with a resin mold as in Patent Document 1, there is a problem that a mold cost is required. In addition, in order to enable the fixing bracket 141 to be screwed to the case 110, the interval between the through holes of the fixing bracket 141 and the interval between the female screws for the bolt 142 formed in the case 110 are highly accurate. Must match. That is, when the core 120 and the fixture 141 are integrally formed, a jig is required for positioning the fixture 141 with respect to the core 120 with high accuracy. For these reasons, the manufacturing cost of the reactor 101 of Patent Document 1 is large.

  The present invention has been made to solve the above problems. That is, an object of the present invention is to provide an inductor with a low manufacturing cost that can prevent direct contact between a core and a case.

  In order to achieve the above object, an inductor according to the present invention is a plate fixed to a case and abutting against the first surface of the core that is proximal to the bottom surface of the case and the side surface of the core and biasing the core A first fixing member that is a spring, and a second fixing member that is fixed to the case and abuts against the second surface of the core that is proximal to the opening of the case and holds the core on the opening side of the case And the first fixing member is disposed between the inner side surface of the case and the side surface of the core, and spreads in a direction along the inner side surface of the case, and on the bottom side of the case A first arm portion that is bent in an L shape from the end portion of the plate-like portion positioned and is fixed to the bottom surface of the case, and from the end portion of the plate-like portion located on the opening side of the case toward the side surface of the core. And a support portion that comes into contact with the first surface of the core is provided at the tip thereof. A second arm portion, fixing the first fixing member to the case, attaching a core to the support portion of the first fixing member, and then fixing the second fixing member to the case Accordingly, the support portion of the first fixing member moves downward, the second arm portion comes into contact with the side surface of the core, and the side surface of the core is urged by the second arm portion. It is configured.

  In the configuration of the present invention, since the first fixing member that is a leaf spring abuts against the core and biases the core as described above, it is not necessary to strictly position the fixing member and the core. A jig or the like for positioning is not required. In addition, according to the configuration of the present invention, the first fixing member is fixed to the case, the core is attached on the support portion of the first fixing member, and the second fixing member is fixed to the case. In this process, the core and the winding can be held in the case while the core is levitated from the case. For this reason, according to the structure of this invention, the inductor with the low manufacturing cost which can prevent the direct contact of a core and a case is implement | achieved.

  The second arm portion is provided with a first bent portion that bends away from the core, and the first arm portion of the second arm portion is fixed when the first and second fixing members are fixed to the case. The bent portion may be in contact with the side surface of the core.

  Further, it is preferable that the support portion of the second arm portion is a second bent portion in which the second arm portion is bent in a direction away from the first surface of the core.

  With such a configuration, damage to the core that may occur due to contact between the edge portion of the second arm portion and the core is prevented.

  The first arm portion extends in a direction toward the core, and the first arm portion is formed with a through hole through which a bolt for fixing the first fixing member to the case is passed. The second arm portion is preferably provided with a notch that allows the through hole to be accessed from the opening side of the case.

  With such a configuration, when the first fixing member is fixed to the case, it is possible to insert a tool from the notch and screw the bolt into the case, and the inductor assembly process becomes simpler.

  In addition, the second fixing member has an elongated main beam portion in which a through hole through which a bolt for fixing the second fixing member to the case is passed is formed at least at one end, and a core is formed from the main beam portion. It is preferable that the plate spring has a contact portion that protrudes toward the second surface and contacts the second surface of the core.

  In addition, the through holes of the second fixing member are formed one by one at both ends in the longitudinal direction of the main beam portion, and the contact portion of the second fixing member is formed at a substantially central portion in the longitudinal direction of the main beam portion. It is good also as composition which has.

  In addition, it is preferable that the width of the main beam portion is reduced from the through hole toward the contact portion.

  With such a configuration, the spring constant of the second fixing member as the leaf spring can be adjusted to an appropriate size.

  Moreover, it is preferable that the corner portion between the main beam portion and the contact portion is rounded.

  With such a configuration, stress concentration at the corner portion is alleviated.

  The contact portion is formed with a third bent portion in which the corresponding contact portion is bent in a direction away from the second surface of the core, and the third bent portion is in contact with the second surface of the core. A configuration is preferable.

  With such a configuration, damage to the core that may occur due to contact between the edge portion of the contact portion and the core is prevented.

  Moreover, it is good also as a structure which has two or more sets of 1st fixing members and 2nd fixing members.

  As described above, according to the present invention, an inductor with a low manufacturing cost that can prevent direct contact between the core and the case is realized.

FIG. 1 is a perspective view of a reactor according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the reactor according to the embodiment of the present invention. FIG. 3 is an exploded view of the core and winding according to the embodiment of the present invention. FIG. 4 is an exploded view of the reactor according to the embodiment of the present invention. FIGS. 5A, 5B, 5C, and 5D are a front view, a left side view, a top view, and a bottom view, respectively, of the first fixing member according to the embodiment of the present invention. FIG. 6 is a side view of the first fixing member according to the embodiment of the present invention in a natural state and a core holding state. FIG. 7 is a perspective view of a reactor according to an embodiment having a conventional configuration.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view of a reactor as an inductor according to the present embodiment. FIG. 2 is a side sectional view of the reactor of the present embodiment. As shown in FIG. 1, the reactor 1 of the present embodiment is one in which two sets of windings 31 and 32 are wound around a substantially O-shaped core 20 and accommodated in a bowl-shaped case 10. One ends (not shown) of the windings 31 and 32 are joined, and the windings 31 and 32 form a circuit connected in series as a whole. Further, the reactor 1 is connected to an electric circuit through the other ends of the windings 31 and 32. The windings 31 and 32 are accommodated in the case 10 without jumping out from the upper end 15 of the case 10.

  In the following description, the vertical direction, the width direction, and the depth direction are defined based on the state in which the reactor 1 is arranged as shown in FIG. That is, in FIG. 2, the side where the opening O of the case 10 is located is the upper side in the vertical direction. In FIG. 2, the right side when the opening of the case 10 is turned up is defined as the right side in the width direction of the reactor 1. The depth direction is a direction perpendicular to both the vertical direction and the width direction, that is, the direction from the front side to the back side of the paper surface in FIG. 2, the front side of the paper surface in FIG. 2 is the front side in the depth direction, and the back side of the paper surface is the back side in the depth direction. Become.

  The assembly procedure of the reactor 1 of this embodiment is demonstrated below. FIG. 3 is an exploded view of the core 20 and the windings 31 and 32 of the present embodiment. As shown in FIG. 3, the core 20 includes a pair of U-shaped cores 21 arranged in the width direction and a pair of I-shaped cores disposed between the arms 21 a on the depth direction side of the pair of U-shaped cores 21. 22a, a pair of I-shaped cores 22b disposed between the arms 21b on the near side in the depth direction of the pair of U-shaped cores 21, between the arms 21a of the U-shaped core 21 and the I-shaped cores 22a, and a pair of I-shaped cores 22a. The gap plate 23a is disposed between the arms 21b and the I-shaped core 22b of the U-shaped core 21 and between the pair of I-shaped cores 22b.

  The arm 21a and the I-shaped core 22a of the U-shaped core 21 and the gap plate 23a are joined by an adhesive. Similarly, the arm 21b and the I-shaped core 22b of the U-shaped core 21 and the gap plate 23b are also joined with an adhesive. One U-shaped core 21, a pair of I-shaped cores 22a, a pair of I-shaped cores 22b, and gap plates 23a and 23b are joined with an adhesive to form a U-shaped core. The windings 32 and 32 are passed through the O-shaped core 20 by passing the winding 32 through the core 22a and the I-shaped core 22b, respectively, and then bonding the other U-shaped core 21 to the gap plates 23a and 23b. The formed block is formed.

  Next, a block including the core 20 and the windings 31 and 32 is accommodated in the case 10. FIG. 4 shows an exploded view of the reactor 1 of the present embodiment. As shown in FIG. 4, in the present embodiment, the first fixing member 40 and the second fixing member 50 are used to fix the core 20 and the windings 31 and 32 to the case 10.

  As shown in FIGS. 2 and 4, one first fixing member 40 is provided on each side in the width direction of the reactor 1. As shown in FIG. 4, the first fixing member 40 has through holes 41 a, and bolts 61 are passed through the through holes 41 a, and then the bolts 61 are arranged on both sides of the bottom surface 11 of the case 10 in the width direction. Since they are provided one by one, they are fixed to the case 10 by being screwed into the screws 11a (FIG. 2). In addition, as shown in FIGS. 1, 2, and 4, one second fixing member 50 is provided on each side of the reactor 1 in the width direction. As shown in FIG. 4, the second fixing member 50 has a long main beam portion 55 extending in the depth direction, and through holes 55 a are formed at both ends of the main beam portion 55 in the depth direction. . As shown in FIG. 4, bolts 62 are passed through the through holes 55a of the second fixing member 50, and then the screws 62a are provided at the four corners of the case 10 (only one is shown in FIG. 4). The second fixing member 50 is fixed to the case 10 by being screwed into the case 10.

  In the present embodiment, the first fixing member 40 and the second fixing member 50 press and hold the core 20 from the upper side and the lower side in the vertical direction, respectively. Further, the pair of first fixing members 40 cooperate to press and hold the core 20 from the outer side in the width direction toward the inner side.

  The characteristics of the first fixing member 40 will be described below. The front view which projected the 1st fixing member 40 of the right side in FIG. 2 to the depth direction, the side view which projected the width direction from the inner side (namely, left side in FIG. 2) of the case 10, the top view which projected from the up-down direction upper side, The bottom views projected from the lower side in the direction are shown in FIGS. 5 (a), (b), (c) and (d), respectively.

  As shown in FIG. 5A, the first fixing member 40 is formed by bending a metal plate such as a stainless steel plate into an L shape at a first corner portion 43 (lower side in the drawing), and further, a first corner portion. It is formed by being bent into a U-shape at a second corner portion 44 on the opposite side (upper side in the drawing) from 43. At this time, the first arm portion 41 formed by L-shaped bending at the first corner portion 43, and the second arm portion 42 formed by U-shaped bending at the second corner portion 44, Face to face.

  As shown in FIGS. 5C and 5D, the through hole 41 a is disposed at the approximate center of the first arm portion 41 in the depth direction. Therefore, as shown in FIG. 2, in a state where the first fixing member 40 is fixed to the case 10, the first arm portion 41 spreads in the direction along the bottom surface 11 of the case 10, and the first The plate-like portion 45 sandwiched between the corner portion 43 and the second corner portion 44 spreads in the direction along the wall surfaces 13 at both ends in the width direction of the case 10.

  As shown in FIGS. 2 and 5 (a), the second arm portion 42 is bent slightly in a U-shape toward the plate-like portion 45 (that is, in a direction away from the core 20) in the middle of the second arm portion 42. A first bent portion 42a is formed. Further, a portion on the distal end side of the second arm portion 42 (a portion closer to the distal end than the bent portion 42a) is folded back in a U shape toward the inner side in the width direction. Furthermore, a second bent portion 42b that is bent slightly downward is formed at the tip of the second arm portion 42. As shown in FIG. 2, in a state where the first fixing member 40 is fixed to the case 10, the first bent portion 42 a of the second arm portion 42 is formed on the side surface 21 c on the outer side in the width direction of the U-shaped core portion 21 of the core 20. At the same time, the second bent portion 42 b of the second arm portion 42 contacts the lower surface 21 d of the U-shaped core portion 21.

  Next, the configuration of the second fixing member 50 will be described. As shown in FIG. 4, the second fixing member 50 is formed from a metal plate such as a stainless steel plate. As described above, the second fixing member 50 has the elongated main beam portion 55. In the state fixed to the case 10, the main beam portion 55 of the second fixing member 50 has the depth direction as the longitudinal direction and the plate thickness direction as the substantially vertical direction.

  A contact portion 51 extending outward in the width direction is formed at a substantially central portion in the longitudinal direction (depth direction) of the main beam portion 55 of the second fixing member 50. The contact portion 51 is bent downward (that is, the upper surface 21e of the U-shaped core portion 21 of the core 20). In addition, as shown in FIG. 2, the tip of the contact portion 51 is formed with a bent portion 51 a that is bent upwardly (that is, in a direction away from the core 20). In the state where the second fixing member 50 is fixed to the case 10, the bent portion 51 a at the tip of the contact portion 51 contacts the upper surface 21 e of the U-shaped core portion 21 of the core 20 as shown in FIG. 2.

  To accommodate the core 20 and the windings 31 and 32 in the case 10, the first fixing member 40 is fixed to the case 10, the core 20 is then placed between the pair of first fixing members 40, and the second fixing member 50 is This is performed by fixing to the case 10. In the present embodiment, after the second fixing member 50 is fixed to the case 10, a resin mold such as epoxy resin is injected into the case 10, and the core 20 and the windings 31 and 32 are more firmly formed in the case 10. Held in.

  A holding mechanism for the core 20 by the first fixing member 40 and the second fixing member 50 will be described below. FIG. 6 is a side view showing the shape of the first fixing member 40 of the present embodiment in a natural state and a state in which the core 20 is held. In FIG. 6, the first fixing member 40 in a natural state is indicated by a broken line, and the first fixing member 40 in a state in which the core 20 is held is indicated by a solid line.

  As shown by a broken line in FIG. 6, in a state where the core 20 is not held, the first bent portion 42 a of the first fixing member 40 is slightly more than the first bent portion 42 a where the core 20 is held. It is located outside in the width direction (right side in the figure). Therefore, when the pair of first fixing members 40 is fixed to the case 10 and the second fixing member 50 is not fixed to the case 10, the distance between the first bent portions 42 a of the pair of first fixing members 40. Becomes larger than the width-direction dimension of the core 20, and the core 20 can be placed on the second bent portion 42b without contacting the first bent portion 42a.

  When the second fixing member 50 is fixed to the case 10 from this state, the bent portion 51b of the contact portion 51 of the second fixing member 50 contacts the core 20 as shown by the solid line in FIG. In other words, it is pushed toward the bottom surface 11 of the case 10. As a result, the plate-like portion 45 and the second arm portion 42 of the first fixing member 40 fall inward in the width direction with the first corner 43 as a fulcrum, and the first bent portion 42 a comes into contact with the side surface of the core 20. The core 20 is energized. As a result, the core 20 is held so as not to move in the width direction. In the present embodiment, as shown in FIG. 2, a gap is provided between the plate-like portion 45 of the first fixing member 40 and the inner side surface 13 of the case 10. The inner side surface 13 is not contacted. For this reason, in a state where the second fixing member 50 is fixed to the case 10, the plate-like portion 45 and the second arm portion 42 of the first fixing member 40 function reliably as a leaf spring having the first corner 43 as a fulcrum. To do.

  In the present embodiment, as described above, the first fixing member 40 biases the core 20 in the width direction (that is, the normal direction of the bonding surface of the U-shaped core 21 and the I-shaped cores 22a and 22b). Thus, a load in the normal direction is applied to the adhesive surface. For this reason, even if shear stress in the surface direction of the bonding surface is applied to the core 20 due to thermal expansion of the core 20 or the like, the bonding is not easily peeled off.

  Further, as described above, the core 20 is pushed downward by fixing the second fixing member 50 to the case 10. At this time, as shown in FIG. 2, the core 20 is between the bent portion 51 b of the contact portion 51 of the second fixing member 50 and the second bent portion 42 b of the second arm portion 42 of the first fixing member 40. Is sandwiched from both ends in the vertical direction. In this state, the main beam portion 55 of the second fixing member 50 is slightly bent upward, and the core 20 is biased downward by the repulsive force. As described above, the second fixing member 50 functions as a leaf spring for biasing the core 20 downward. The core 20 disposed on the second bent portion 42b of the second arm portion 42 of the first fixing member 40 includes the bent portion 51b of the second fixing member 50 and the second bent portion 42b of the first fixing member 40. Is held in the vertical direction. Here, the main beam portion 55 of the second fixing member 50 is narrowed down in width (width direction dimension) toward the center in the depth direction. By setting the main beam portion 55 to such a shape, the spring constant of the second fixing member 50 as a leaf spring is adjusted to an appropriate size. Further, the corner portion between the main beam portion 55 and the contact portion 51 is rounded so that the stress concentration on the corner portion is alleviated.

  As described above, since the lower surface 21d of the U-shaped core portion 21 of the core 20 and the first fixing member 40 are in contact with each other at the second bent portion 42b, the edge portion at the tip of the second arm portion 42 is provided. 42d and the core 20 do not contact, and the core 20 is not damaged by the edge part 42d, and it does not break. Similarly, since the upper surface 21c of the U-shaped core portion 21 of the core 20 and the second fixing member 50 are in contact with each other at the bent portion 51b, the edge portion 51a at the tip of the contact portion 51 of the second fixing member 50 is used. And the core 20 do not come into contact with each other, and the core 20 is not damaged and damaged by the edge portion 51a.

  In the present embodiment, as shown in FIGS. 5B and 5C, a U-shaped notch 42 c is formed at the approximate center in the depth direction of the second arm 42. As shown in FIGS. 5B and 2, the notch 42 c and the through hole 41 a of the first fixing member 40 are arranged side by side in the vertical direction. Therefore, the reactor 1 of the present embodiment can pass a tool (such as a wrench) through the notch 42c, and can screw the bolt 61 into the female screw 11a of the case 10 without causing the tool and the first fixing member 40 to interfere with each other. .

  In a state where the core 20 and the windings 31 and 32 are held and accommodated in the case 10, the core 20 is held in the case 10 by the first fixing member 40 and the second fixing member 50 as described above. It has become. In this state, the core 20 is lifted from the bottom surface 11 of the case 10. As described above, in the reactor 1 of the present embodiment, the core 20 and the bottom surface of the case 10 are not in direct contact. Therefore, the vibration of the core 20 that may occur when the reactor 1 is used (when the coils 31 and 32 are energized). The transmission to the case 10 is greatly reduced, and the noise during use of the reactor 1 can be greatly reduced. Particularly in the present embodiment, the fulcrum as the leaf spring of the second arm portion 42 of the first fixing member 40 is the first corner 43. For this reason, the second arm 42 is a leaf spring having a long span (that is, a small spring constant) extending from the first corner 43 to the bent portion 42a and the distal end portion 42b through the second corner 44, and vibration generated in the core 20 Can be absorbed efficiently.

  In the embodiment of the present invention described above, the first fixing member 40 and the second fixing member 50 are provided in two sets, one set on each side in the width direction of the reactor 1. It is not limited to said structure, It is good also as a structure by which only 1 set of the 1st fixing member 40 and the 2nd fixing member 50 is provided in the width direction one side. In this case, the second arm 42 of the first fixing member 40 presses the core 20 against the inner peripheral side surface 13 of the case 10 opposite to the side where the first fixing member 40 is provided. Energize.

  Moreover, in this embodiment, although the 2nd fixing member 50 is a leaf | plate spring which uses both ends as a support point, this invention is not limited to said structure. For example, a cantilever-shaped leaf spring having only one end as a support point, or another type of spring may be used as the second fixing member 50.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Case 12 Bottom face 13 Inner side face 20 Core 31, 32 Winding 40 1st fixing member 42 2nd arm 50 2nd fixing member

Claims (10)

A bowl-shaped case with an open upper surface ;
A core housed in the case;
A winding wound around a portion of the core;
A first fixing member that is fixed to the case and is a leaf spring that abuts against the lower surface of the core and the side surface of the core that is proximal to the bottom surface of the case and biases the core;
A second fixing member fixed to the case and contacting the upper surface of the core proximal to the opening of the case to hold the core on the opening side of the case;
Have
The first fixing member is
A plate-like portion disposed between the inner side surface of the case and the side surface of the core, and extending in a direction along the inner side surface of the case;
A first arm portion fixed to the bottom surface of the case is bent in an L shape from the plate portion of the lower end portion located on the bottom side of the case,
A second arm portion which is folded in a U shape from the upper end of the plate-like portion located on the opening side of the case toward a side of the core, with its tip, the lower surface of the core Supporting at a position that floated from the bottom of the case ,
Have
The lower surface of the core is brought into contact with the distal end portion and the second fixing member is fixed to the case, whereby the distal end portion is pushed downward together with the core by the second fixing member, and the second The arm portion of the core falls down and abuts against the side surface of the core to urge the side surface, and the core is held at a position floating from the bottom surface of the case and at a position away from the inner side surface of the case. ,
Inductor. The second arm portion is provided with a first bent portion that is bent in a direction away from the core,
When the first and second fixing members are fixed to the case, the first bent portion of the second arm portion contacts the side surface of the core ;
The inductor according to claim 1. The distal end portion of the second arm portion has a second bent portion obtained by bending the second arm portion in a direction away from the lower surface of the core .
The inductor according to claim 1 or 2. The first arm portion extends in a direction toward the core;
The first arm portion has a through hole through which a bolt for fixing the first fixing member to the case is passed,
The second arm portion is provided with a notch that allows the through hole to be accessed from the opening side of the case .
The inductor according to any one of claims 1 to 3. The second fixing member is
An elongated main beam portion having a through-hole through which a bolt for fixing the second fixing member to the case is formed at least at one end;
It abuts the abutment on the upper surface of the core projects toward the upper surface of the core from the main beam portion,
A leaf spring having,
The inductor according to any one of claims 1 to 4. The through hole of the second fixing member is
One is formed at each longitudinal end of the main beam part,
Contact portion of the second fixing member,
It is formed at a substantially central part in the longitudinal direction of the main beam part ,
The inductor according to claim 5. The width of the main beam portion is
It is smaller as it goes from the through hole to the contact portion ,
The inductor according to claim 5 or 6. The corner portion between the main beam portion and the contact portion is rounded ,
The inductor according to any one of claims 5 to 7. The contact portion is formed with a third bent portion that is bent in a direction away from the upper surface of the core, and the third bent portion contacts the upper surface of the core .
The inductor according to any one of claims 5 to 8. A plurality of sets of the first fixing member and the second fixing member ;
The inductor according to any one of claims 1 to 9.

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