JP5691722B2 - Voltage converter - Google Patents

Description

  The present invention relates to a voltage conversion device including a transformer and a housing that houses the transformer.

  The voltage converter is used for charging a low-voltage auxiliary battery from a high-voltage main battery in a hybrid vehicle having both an internal combustion engine and an electric motor as a drive source, an electric vehicle equipped with an electric motor as a drive source, and the like. It is done. Further, it is used to charge a high-voltage main battery such as a hybrid vehicle or an electric vehicle from a standard AC outlet in a general home via a dedicated charging cable. As a voltage converter, for example, as disclosed in Patent Document 1, a bobbin having a hollow portion into which a core is inserted and a pair of flanges, a first winding wound around a pair of flanges of the bobbin, and a second winding Some have a winding and a bobbin terminal for holding each lead wire of the first winding and the second winding. The bobbin terminal is fixed to a bobbin press-fitted into a hole previously drilled in the bobbin flange. Thereby, each leader line of the 1st winding and the 2nd winding is being fixed to the voltage converter.

JP-A-6-275446

  The voltage conversion device having a structure in which the bobbin terminal holding the lead wire as described above is fixed to the flange of the bobbin is suitable for the wire diameter when the wire diameters of the first winding and the second winding are changed. Therefore, it is necessary to change the size of the bobbin terminal. Therefore, it is necessary to change the size of the hole for fixing the bobbin terminal to the flange. Therefore, in order to cope with the first winding and the second winding having different wire diameters, there is a problem that a plurality of types of flanges having bobbin terminals corresponding to the wire diameters and holes corresponding to the bobbin terminals are required.

  Then, this invention is made | formed in view of such a problem, and it aims at providing the voltage converter which can respond | correspond to the some 1st winding and 2nd winding from which a wire diameter differs. .

In order to solve the above-mentioned problem, the invention according to claim 1 is a voltage converter including a bobbin that winds a primary coil and a secondary coil, and a core made of a magnetic body that houses the bobbin, The primary coil includes a primary winding portion wound around the bobbin and primary side terminals drawn from both ends of the primary winding portion, and the secondary coil is wound around the bobbin. A secondary winding part, and a secondary terminal pulled out from both ends of the secondary winding part, the bobbin winding the primary coil and the secondary coil; A flange portion that prevents the primary coil and the secondary coil from falling off from the winding portion, and the primary side terminal or the secondary side terminal is electrically connected to the outside through a terminal connection portion. The terminal connection part is the primary side terminal or the secondary side terminal. A terminal holding portion to be held, a fixing portion for fixing the terminal connecting portion to the flange portion, and a conducting portion that is connected to the primary side terminal or the secondary side terminal via the terminal holding portion and is electrically connected to the outside. The primary side terminal or the secondary side terminal is drawn out to the outside of the bobbin in a direction perpendicular to the axial direction of the bobbin, and the bent from the drawn part to the axial direction And an extended portion extending in a direction parallel to the axial direction from the bent portion, and a distal end portion of the extended portion is held by being placed on the terminal holding portion, and the extended portion In the extending direction of the protruding portion, the terminal holding portion, the fixing portion, and the conducting portion are arranged on a straight line in this order .

  If comprised in this way, the fixing | fixed part which fixes a terminal connection part to a flange, and the terminal holding part holding a primary side terminal or a secondary side terminal can be arrange | positioned in another place. Thereby, even if the wire diameter of a primary side terminal or a secondary side terminal changes, it is not necessary to change the fixing | fixed part which fixes a terminal connection part to a flange part. Therefore, according to the present invention, the wire diameter is compared with the configuration in which the terminal holding portion for holding the primary side terminal or the secondary side terminal and the fixing portion for fixing the terminal connection portion to the flange are arranged at the same place. Can correspond to a plurality of primary coils and secondary coils having different.

  Invention of Claim 2 is the voltage converter of Claim 1, Comprising: The said primary coil and the said secondary coil are comprised by the assembly | assembly of the several strand which equips the outer periphery of conducting wire with the insulating film. The width in the width direction of the primary side terminal and the secondary side terminal is longer than the length in the width direction of the conducting portion.

  In the case where a primary side terminal and a secondary side terminal constituted by a plurality of strands each having an insulating film on the outer periphery of the conducting wire are to be conducted with the conducting portion through the terminal holding portion, the insulation of each strand It is necessary to peel off the film and connect to the terminal holding part. Therefore, it is necessary to heat-press the primary side terminal or the secondary side terminal and the terminal holding part with a large heat. Here, according to the said structure, the fixing | fixed part which fixes a terminal holding part and a terminal connection part to a flange part can be arrange | positioned in another place. Therefore, according to this invention, when fixing a primary side terminal or a secondary side terminal to a terminal holding part, it can prevent that a big heat is added to a fixing | fixed part and a flange part.

  Invention of Claim 3 is the voltage converter of Claim 1 or 2, Comprising: The said terminal connection part is provided with the said some fixing | fixed part, and is fixed in multiple places with respect to the said flange part. It is characterized by that.

  If comprised in this way, a terminal connection part will be fixed to a flange part in multiple places. Therefore, according to this invention, the fixing performance with respect to the flange of a terminal connection part can be improved compared with the structure which fixes a terminal connection part with respect to a flange at one place.

The circuit diagram which shows the voltage converter in a present Example. The exploded perspective view of a voltage converter. The top view of a terminal connection part. The front view which shows the drawer state of a primary side terminal and a secondary side terminal. The side view of FIG. FIG. 5 is a top view of FIG. 4. The front view of the voltage converter in another Example.

Example 1
Embodiments of the present invention will be described below with reference to the drawings. In the description after FIG. 1, the same components are denoted by the same reference numerals and description thereof is omitted.

  FIG. 1 shows a circuit diagram of the voltage conversion device 1. As shown in FIG. 1, the voltage conversion apparatus 1 includes a primary coil 11 and a secondary coil 12 that constitute a transformer that converts an input voltage, diodes 13a and 13b that rectify a transformed AC current, and a rectified DC current. And a smoothing capacitor 14 that smoothes the ripple current included in the.

The primary coil 11 includes a first winding portion 113 and primary side terminals 111 and 112. The secondary coil 12 includes a second winding part 123 and secondary terminals 121 and 122. The first winding part 113 and the second winding part 123 are formed to have different numbers of turns. The first winding portion 113 and the second winding portion 123 constitute a transformer T. Current before voltage conversion converted into alternating current by the inverter 17 is input to the primary side terminals 111 and 112. Electromagnetic induction occurs between the primary coil 11 and the secondary coil 12 due to the alternating current flowing through the first winding portion 113 of the primary coil 11, and voltage conversion is performed on the second winding portion 123 of the secondary coil 12. AC current flows. The anodes of the diodes 13a and 13b are connected to the secondary side terminals 121 and 122 of the secondary coil 12, respectively. The cathodes of the diodes 13 a and 13 b are connected to the positive output terminal 15 of the voltage conversion device 1. The secondary terminal 122 of the secondary coil 12 is also connected to the negative output terminal 16 of the voltage converter 1. As a result, the alternating current after voltage conversion that has flowed through the second winding portion 123 of the secondary coil 12 is rectified by the diodes 13a and 13b, and the direct current is extracted. Further, a smoothing capacitor 14 is connected between the output terminals 15 and 16 of the voltage conversion device 1 to absorb the ripple current contained in the rectified DC current and stabilize the DC current. The voltage conversion device 1 can be used for a vehicle such as a hybrid vehicle or an electric vehicle. For example, a current of about 300 V is applied to the inverter 17. The applied current is stepped down to about 14 V by the voltage converter 1. And in-vehicle components, such as a car air-conditioner and a light, can be driven with the electric current taken out from output terminals 15 and 16 of voltage converter 1.

  FIG. 2 is an exploded perspective view of the voltage conversion device 1. FIG. 3 shows a plan view of the terminal connection portion 4. FIG. 4 is a front view showing the pulled-out state of the primary side terminals 111 and 112 and the secondary side terminals 121 and 122. FIG. 5 shows a side view of FIG. FIG. 6 shows a top view of FIG.

  As shown in FIGS. 2 to 6, the voltage conversion apparatus 1 includes a core 2, a bobbin 3, a primary coil 11, a secondary coil 12, and a terminal connection unit 4.

  The core 2 formed of a magnetic material is formed by a pair of upper core member 21 and lower core member 22. Each of the upper core member 21 and the lower core member 22 includes a main body portion 23, a side leg portion 24, and a central magnetic leg portion 25. Specifically, as shown in FIG. 2, the rectangular side leg portions 24 are formed so as to protrude from both ends in the longitudinal direction of the flat plate-like main body portion 23 with respect to the normal direction of the main surface of the main body portion 23. Has been. Here, the main surface of the main body 23 refers to two opposing surfaces having the largest area. A cylindrical central magnetic leg portion 25 is formed so as to protrude from a substantially central portion in the longitudinal direction of the flat plate-like main body portion 23 with respect to the normal direction of the main surface of the main body portion 23. Further, the side leg portion 24 is formed with a slightly larger protrusion than the central magnetic leg portion 25. Therefore, when the upper core member 21 and the lower core member 22 are combined with the side leg portions 24 and the central magnetic leg portions 25 of the upper core member 21 and the lower core member 22, the upper core member 21 and the lower core member 22 are combined. The end portions of the side leg portions 24 are in contact with each other, and an air gap including a slight gap is formed between the end portions of the central magnetic leg portions 25 of the upper core member 21 and the lower core member 22.

  The bobbin 3 includes a first bobbin 31 that winds the primary coil 11 and a second bobbin 32 that winds the secondary coil 12. The first bobbin 31 includes a primary winding portion 311 that winds the primary coil 11, and a first flange portion 312 and a second flange portion 313 that prevent the primary coil 11 from dropping from the primary winding portion 311. And. The second bobbin 32 includes a secondary winding part 321 for winding the secondary coil 12, and a third flange part 322 and a fourth flange part 323 that prevent the secondary coil 12 from falling off the secondary winding part 321. And. Moreover, the 1st bobbin 31 and the 2nd bobbin 32 are formed with resin.

  As shown in FIG. 2, the primary winding part 311 and the secondary winding part 321 have a cylindrical shape. The cylindrical primary winding portion 311 and the secondary winding portion 321 are hollow holes 33 that penetrate from one end of the primary winding 311 in the axial direction (hereinafter referred to as the axial direction) to the other end. Is formed. Further, spiral threads are formed on the outer peripheral surfaces of the cylindrical primary winding portion 311 and the secondary winding portion 312. In the first embodiment, the primary coil 11 and the secondary coil 12 are wound between the threads of the threads formed on the primary winding portion 311 and the secondary winding portion 312.

  The 1st flange 312 and the 2nd flange part 313 are formed so that it may protrude with respect to the direction orthogonal to an axial direction in the periphery of the both ends in an axial direction. The 3rd flange 322 and the 4th flange part 323 are formed so that it may protrude with respect to the direction orthogonal to an axial direction in the periphery of the both ends in an axial direction.

  When viewed from the axial direction, the outer shapes of the first flange portion 312, the second flange portion 313, and the fourth flange portion 323 are formed in a circular shape. The outer shape of the third flange portion 322 has a shape obtained by combining a semicircular shape and a rectangular shape. Further, the third flange portion 322 is formed so that the protruding amount on the rectangular shape side of the third flange portion 322 is larger than the first flange portion 312, the second flange portion 313, and the fourth flange portion 323.

  A plurality of notches 34 for fixing a terminal connecting portion 4 to be described later are formed on the rectangular shape side of the third flange portion 322. Specifically, the number of primary side terminals 111 and 112 drawn from the primary coil 11 and the number of secondary side terminals 121 and 122 drawn from the secondary coil 12, that is, four notches 34 are formed. ing. The four notches 34 are linearly formed on the periphery of the third flange portion 322 on the rectangular shape side.

  The primary coil 11 includes a primary winding portion 113 wound around the central magnetic leg portion 25 via the primary winding portion 311 and a primary side terminal 111 drawn from both ends of the primary winding portion 113. , 112. Similarly, the secondary coil 12 has a secondary winding portion 123 wound around the central magnetic leg portion 25 via the secondary winding portion 321, and a secondary side drawn from both ends of the secondary winding portion 123. Terminals 121 and 122 are provided.

  The primary coil 11 and the secondary coil 12 are so-called litz wires in which a plurality of strands each having an insulating film such as polyamideimide are gathered around the outer periphery of the conducting wire. Further, when viewed from the axial direction, the primary coil 11 and the secondary coil 12 are arranged to overlap each other. FIG. 2 shows a state in which the primary coil 11 is wound around the primary winding portion 311 and the secondary coil 12 is wound around the secondary winding portion 321. Further, the primary side terminals 111 and 112 of the primary coil 11 and the secondary side terminals 121 and 122 of the secondary coil 12 are omitted.

  As shown in FIG. 3, the terminal connecting portion 4, the terminal holding portion 41, the conducting portion 42, and the fixing portion 43 are provided.

  The terminal holding part 41 includes a placement part 411 for placing a connection line 116, which will be described later, and a clamping part 412 for fixing the connection line 116. The clamping part 412 is formed so as to protrude from both sides of the mounting part 411 in the width direction. The mounting portion 411 and the clamping portion 412 are integrally formed and have a flat plate shape as a whole.

  The conduction part 42 is a terminal connected to the outside of the voltage conversion device 1 and is formed so as to protrude from the terminal holding part 41. In Example 1, the width of the mounting portion 411 in the direction in which the sandwiching portion 412 is disposed is formed to be longer than the width of the conducting portion 42.

  The fixed portion 43 is formed by a first protrusion 431 and a second protrusion 432. The first projecting portion 431 and the second projecting portion 432 are formed in the conducting portion 42 so as to be juxtaposed with the sandwiching portion 412. A gap is formed between the first protrusion 431 and the second protrusion 432. In the first embodiment, the length of the gap between the first protrusion 431 and the second protrusion 432 is slightly larger than the thickness of the third flange 322.

  As shown in FIG. 3, the terminal connection portion 4 is positioned in the order of the terminal holding portion 41, the fixing portion 43, and the conduction portion 42 when viewed from a connection line 116 described later. In other words, the terminal holding part 41, the fixing part 43, and the conduction part 42 are positioned in a straight line.

  When combining the core 2, the bobbin 3, the primary coil 11, the secondary coil 12, and the terminal connection portion 4, the first flange portion 312 of the first bobbin 31 and the fourth flange portion 323 of the second bobbin portion 32 are in contact with each other. Touch. Thereby, the hollow hole 33 of the 1st bobbin 31 and the 2nd bobbin 32 is connected, and it is the 2nd bobbin from the 2nd flange part 313 of the 1st bobbin part 31, ie, the 2nd flange part 313 of the 1st bobbin part 31 in an axial direction. A hole penetrating to the third flange portion 322 of the portion 32 is formed.

  When the side leg portions 24 and the central magnetic leg portions 25 of the upper core member 21 and the lower core member 22 are opposed to each other and the upper core member 21 and the lower core member 22 are combined, the third flange portion 322 of the second bobbin 32 is the upper portion. It arrange | positions so that the main surface of the main-body part 23 of the core member 21 may contact | abut. Similarly, the second flange portion 313 of the first bobbin 31 is disposed so as to contact the main surface of the main body portion 23 of the lower core member 22. Further, the central magnetic leg portion 25 of the upper core member 21 is disposed so as to be inserted into the hollow hole 33 of the second bobbin 32. Similarly, the central magnetic leg portion 25 of the lower core member 22 is disposed so as to be inserted into the hollow hole 33 of the first bobbin 31. Further, the tips of the side leg portions 24 of the upper core member 21 and the lower core member 22 come into contact with each other. As a result, the bobbin 3 around which the primary coil 11 and the secondary coil 12 are wound is positioned in the space formed by the main body portion 23 and the side leg portion 24 of the upper core member 21 and the lower core member 22. .

  Next, the principal part of Example 1 is demonstrated.

  FIG. 4 is a front view showing a drawn state of the primary side terminals 111 and 112 of the primary coil 11 and the secondary side terminals 121 and 122 of the secondary coil 12. FIG. 5 shows a side view of FIG. FIG. 6 shows a top view of FIG. In FIG. 5, the primary side terminal 112 drawn from the primary coil 11 and the secondary side terminals 121 and 122 drawn from the secondary coil 12 are omitted.

  The primary side terminal 111 drawn out from the primary coil 11 will be described. Since the primary side terminal 112 has the same shape, the description thereof is omitted.

  As shown in FIGS. 4 and 5, the primary side terminal 111 is drawn from both ends of the primary winding portion 113 in the direction perpendicular to the axial direction, and from the drawn portion 114 in the axial direction. A bending portion 115 that is bent with respect to the bending portion 115 and a connection line 116 that is disposed in parallel with the axial direction from the bending portion 115 are provided.

  Specifically, the lead wire 114 of the primary side terminal 111 is drawn from between the first flange portion 312 and the second flange portion 313. When viewed from the axial direction, the lead-out portion 114 is formed so as to be located outside the outer shape of the first flange portion 312, the second flange portion 313, and the fourth flange portion 323 and inside the outer shape of the third flange portion 322. ing.

  The distal end portion of the connecting wire 116 disposed in parallel with the axial direction from the bent portion 115 is disposed on the placement portion 411 of the terminal holding portion 41. Thereafter, the pair of sandwiching portions 412 are bent into a C shape so as to wrap the connection line 116. And the clamping part 412 is heat-pressed in the state in which the pair of clamping parts 412 envelops the connection wire 116, and heat-caulking is performed while peeling off the insulating film of each strand constituting the litz wire. Thereby, the terminal holding | maintenance part 41 and the connection line 116 are conduct | electrically_connected, and are fixed. Therefore, the conducting part 42 protruding from the terminal holding part 41 and the connection line 116 are conducted, and the voltage conversion device 1 can be connected to the outside via the conducting part 42. Then, the terminal connection portion 4 and the notch portion 34 are combined, the rectangular shape side of the third flange portion 322 is sandwiched between the first protrusion portion 431 and the second protrusion portion 432, and both are fixed, and the primary terminal 111 Positioning.

  Further, the secondary side terminals 121 and 122 drawn from the secondary coil 12 are drawn from between the third flange portion 322 and the fourth flange portion 323, and the primary side terminal 111 of the primary coil 11. The other structures are the same except for the above.

  Next, the effect of Example 1 is demonstrated.

  In the terminal connection part 4 in the first embodiment, the fixing part 43 that is fixed to the first flange part 312 and the terminal holding part 41 that holds the primary side terminals 111 and 112 or the secondary side terminals 121 and 122 are provided in different places. It is arranged. Thereby, even if the wire diameter of the primary side terminals 111 and 112 or the secondary side terminals 121 and 122 changes, it is not necessary to change the fixing | fixed part 43 which fixes the terminal connection part 4 to the 3rd flange part 322. FIG. Therefore, the terminal holding part 41 that holds the primary side terminals 111 and 112 or the secondary side terminals 121 and 122 and the fixing part 43 that fixes the terminal connection part 4 to the third flange part 322 are arranged at the same place. Compared to the first coil 11 and the secondary coil 12 having different wire diameters can be accommodated.

  Moreover, the primary coil 11 and the secondary coil 12 are comprised with what is called a litz wire formed by a plurality of strands having an insulating film on the outer periphery of the conducting wire. The length in the width direction is longer than the length in the width direction of the conducting portion 42. Here, when the primary side terminals 111 and 112 and the secondary side terminals 121 and 122 are to be conducted with the conducting part 42 via the terminal holding part 41, the insulating film of each element wire is peeled off and the terminal holding part 41. Need to connect with. Therefore, it is necessary to heat and press the primary side terminals 111 and 112 or the secondary side terminals 121 and 122 and the terminal holding part 41 with large heat. According to the above configuration, since the terminal holding portion 41 and the fixing portion 43 that fixes the terminal connecting portion 4 to the third flange portion 322 can be arranged at different locations, the primary side terminal or 111 is placed on the terminal holding portion 41. , 112 can prevent large heat from being applied to the fixing portion 43 and the third flange portion 322 when the secondary terminals 121 and 122 are fixed.

  As mentioned above, although the preferable Example of this invention was described, this invention is not limited to the said Example, As long as it exists in the technical scope of this invention, you may deform | transform as follows.

  In the above embodiment, an air gap is formed between the central magnetic leg portions 25 of the upper core portion 21 and the lower core portion 22, but no air gap is formed between the central magnetic leg portions 25. The portions 25 may be brought into contact with each other.

  In the above embodiment, the terminal connection portion 4 is fixed to the third flange portion 322, but may be fixed to the first flange portion 312, the second flange portion 313, or the fourth flange portion 323. Further, as shown in FIG. 7, the terminal connection portion 4 may be fixed to a plurality of locations of the first flange portion 312, the second flange portion 313, the third flange portion 322, or the fourth flange portion 323.

  In the above embodiment, the primary terminals 111 and 112 and the secondary terminals 121 and 122 are drawn in the same direction, but the primary terminals 111 and 112 and the secondary terminals 121 and 122 are in different directions. You may withdraw.

DESCRIPTION OF SYMBOLS 1 Voltage converter 11 Primary coil 111,112 Primary side terminal 113 Primary winding part 114 Lead part 115 Bending part 116 Connection line 12 Secondary coil 121,122 Secondary side terminal 123 Secondary winding part 2 Core 21 Upper core member 22 Lower core member 23 Body portion 24 Side leg portion 25 Central magnetic leg portion 3 Bobbin 31 First bobbin 311 Primary winding portion 312 First flange portion 313 Second flange portion 32 Second bobbin 321 Secondary winding Portion 322 Third flange portion 323 Fourth flange portion 33 Hollow hole 34 Notch portion 4 Terminal connection portion 41 Terminal holding portion 411 Placement portion 412 Holding portion 42 Conducting portion 43 Fixing portion 431 First protrusion portion 432 Second protrusion portion

Claims (3)

A bobbin (3) for winding the primary coil (11) and the secondary coil (12);
A voltage converter (1) comprising a core (2) made of a magnetic material that houses the bobbin (3),
The primary coil (11) includes a primary winding (113) wound around the bobbin (3) and a primary terminal (111) drawn from both ends of the primary winding (113). 112)
The secondary coil (12) includes a secondary winding part (123) wound around the bobbin (3), and a secondary terminal (121) drawn from both ends of the secondary winding part (123). 122),
The bobbin (3) includes winding parts (311 and 321) for winding the primary coil (11) and the secondary coil (12), and the primary coil (311 and 321) from the primary coil (311 and 321). 11) and flange portions (312, 313, 322, 323) for preventing the secondary coil (12) from falling off,
The primary side terminals (111, 112) or the secondary side terminals (121, 122) are electrically connected to the outside via the terminal connection part (4),
The terminal connection part (4) includes a terminal holding part (41) for holding the primary terminal (111, 112) or the secondary terminal (121, 122), and the terminal connection part (41). A fixing part (43) for fixing to the flange parts (312, 313, 322, 323), and the primary terminal (111, 112) or the secondary terminal (121, 112) via the terminal holding part (41). 122) and a conduction portion (42) that conducts to the outside ,
The primary side terminals (111, 112) or the secondary side terminals (121, 122) are pulled out to the outside of the bobbin (3) in a direction perpendicular to the axial direction of the bobbin (3). ), A bent portion (115) bent in the axial direction from the lead portion (114), and an extended portion (116) extending in a direction parallel to the axial direction from the bent portion (115),
The tip of the extension part (116) is held by being placed on the terminal holding part (41),
In the extending direction of the extension part (116), the terminal holding part (41), the fixing part (43), and the conduction part (42) are arranged on a straight line in this order,
The voltage converter (1) characterized by these. The primary coil (11) and the secondary coil (12) are composed of a plurality of strands each having an insulating film on the outer periphery of a conducting wire,
The length in the width direction of the primary side terminals (111, 112) and the secondary side terminals (121, 122) is longer than the length in the width direction of the conducting portion (42).
The voltage converter (1) according to claim 1, characterized by: The terminal connection portion (4) includes a plurality of the fixing portions (43), and is fixed at a plurality of positions with respect to the flange portions (312, 313, 322, 323),
The voltage converter (1) according to claim 1 or 2, characterized in that

Images