JP6555754B2 - Core case structure - Google Patents

Description

  The present invention relates to a core case structure used for a choke coil such as a noise filter.

  Conventionally, a noise filter composed of a choke coil and a capacitor is a device that prevents an electronic device from malfunctioning due to noise entering the electronic device from the outside via a power line, a communication line, etc. Indispensable.

  The choke coil of the noise filter has a structure in which a core member such as ferrite is accommodated in a core case, and the coil is wound around the outside of the core case.

  FIG. 6 shows a conventional core case structure in which one core member is housed in one stage with a three-phase three-wire system. FIG. 6 (A) shows an assembled state, and FIG. 6 (B) shows an assembled / disassembled state. Yes.

  As shown in FIG. 6, the core case 100 </ b> A includes three types of parts including an upper core case part 102, a lower core case part 104, and a connecting member 106. The upper core case component 102 is formed with a cylindrical hole 102a at the center, and an annular storage portion 102b is formed on the lower side coaxially with the cylindrical hole 102a. The slit groove 102d is divided into a plurality of locations on the inner periphery of the cylindrical hole 102a. A protruding portion 102c having the shape is formed in the axial direction.

  The lower core case component 104 has a cylindrical hole 104a formed in the center, and an annular storage portion 104b that opens coaxially with the cylindrical hole 104a. The slit groove 104d is divided into a plurality of locations on the inner periphery of the cylindrical hole 104a. A protruding portion 104c having the shape is formed in the axial direction.

  The connecting member 106 is provided with three fitting ribs 106 a radially corresponding to the slit grooves 102 d and 104 d of the upper core case component 102 and the lower core case component 104, and is formed in each core case 102 and 104. The core case 100A is completed by fitting and fixing the fitting rib 106a to the slit grooves 102d and 104d in a state where the ferrite core member 108 is housed in the annular housing portions 102b and 104b. Finally, a choke coil is manufactured by winding a coil corresponding to each phase of the three-phase alternating current between the coil partition walls 102e and 104e connected to the outside of the protrusions 102c and 104c.

  FIG. 7 shows a conventional core case structure with a three-phase three-wire system in which core members are housed in two stages. FIG. 7A shows an assembled state, and FIG. 7B shows an assembled and disassembled state. .

  As shown in FIG. 7, the core case 100 </ b> B includes four types of parts including an upper core case part 102, a lower core case part 110, a spacer 112, and a connecting member 114. The upper core case component 102 is the same as the conventional structure of FIG. 6, but the lower core case component 110 is dimensioned so that the core member 108 is accommodated in two stages through the spacer 112 at the depth of the annular accommodating portion 110a. This is different from the lower core case component 104 in FIG. The connecting member 114 has a high fitting rib 114 a corresponding to the housing of the two-stage core member 108.

  In the core case 100B, the core members 108 are accommodated in two stages through the spacers 112 in the annular accommodating portions 102a and 110a of the upper core case component 102 and the lower core case component 110, and the core cases 102 and 110 are provided. The core case 100B is completed by fitting and fixing the fitting ribs 114a of the connecting member 114 in the slit grooves 102d and 110d, and finally, the core case 100B is connected to the outside of the protrusions 102c and 110c. A choke coil is manufactured by winding a coil corresponding to each phase of the three-phase alternating current between the coil partition walls 102e and 110e.

  FIG. 8 shows a conventional core case structure in which a three-phase three-wire amorphous core member is housed in two stages. FIG. 8A shows an assembled state, and FIG. 8B shows an assembled and disassembled state. Show.

  As shown in FIG. 8, the core case 100 </ b> C includes four types of parts including four core case parts 116, three upper fixing parts 118, three lower fixing parts 120, and a connecting member 114. . The connecting member 114 is the same as the conventional structure of FIG.

  In the core case 100C, since the amorphous core members 122 arranged in two stages need to secure a space for each core, the amorphous case member 116a is formed in an annular storage portion 116a in which two core case components 116 face each other. The core parts 122 are accommodated and overlapped, and attached so that the upper fixing part 118 and the lower fixing part 120 are sandwiched in three places of the annular storage part 116a, and the slit grooves 118d of the upper fixing part 118 and the lower fixing part 120 are attached. , 120d, the fitting rib 114a of the connecting member 114 is fitted and fixedly connected to complete the core case 100C. Finally, the coil partition wall continuously provided outside the protruding portions 118c, 120c. A choke coil is manufactured by winding a coil corresponding to each phase of three-phase alternating current between 118e and 120e.

Japanese Patent Laying-Open No. 2015-170626

  However, in such a conventional core case structure, for example, when the three types of core cases 100A, 100B, and 100C shown in FIGS. 6 to 8 are manufactured, the upper core case component 102 and the lower core case are formed. Nine types of parts including a part 104, a lower core case part 110, a spacer 112, a core case part 116, two types of connecting members 106 and 114, an upper fixing part 118, and a lower fixing part 120 are required. Correspondingly, nine types of molds are required, and the manufacture and management of the core case components are complicated due to the large number of types of components, resulting in a problem that the manufacturing cost increases.

  The present invention provides a core case structure that can improve the production efficiency and reduce the cost by allowing the core case corresponding to the difference in the number of steps of the core member and the material of the core member to be configured by a small number of types of core case parts. For the purpose.

(Core case structure)
The present invention provides a core case structure,
The upper core case is formed in a U-shaped cross-sectional shape with an annular housing portion opened downward and coaxially with the cylindrical hole, and the ridge portion having slit grooves divided into a plurality of locations on the inner periphery of the cylindrical hole is formed in the axial direction. Parts,
An upper annular storage portion and a lower annular storage portion that are coaxial with the cylindrical hole are formed in an H-shaped cross-sectional shape opened in the vertical direction, and a ridge portion having slit grooves divided into a plurality of locations on the inner periphery of the cylindrical hole is provided. One or more intermediate core case parts formed in the axial direction;
The annular housing is coaxially formed with the cylindrical hole and is formed in a U-shaped cross-sectional shape with an upward opening opposite to the annular housing of the upper core case part , and has slit grooves divided into a plurality of locations on the inner periphery of the cylindrical hole. A lower core case part in which the protrusion is formed in the axial direction;
The fitting cores corresponding to the slit grooves of the upper core case component, the one or more intermediate core case components, and the lower core case component are arranged radially, and each core case component is stacked in the axial direction. fitting ribs by Rukoto be fitted into a plurality of slit grooves protrusions provided continuously in the axial direction of the cylindrical bore of the casing part, and a connecting member for connecting and fixing the core case part,
With
The depth of each annular storage part of each core case part is the same, and the combined depth of both annular storage parts in a state where each core case part is stacked corresponds to the thickness of the core member to be stored. Depth,
In a state where each core case part is connected and fixed by the connecting member, the core member is stored in a space formed by the annular storage part of the upper core case part and the annular storage part above the intermediate core case part, and the intermediate core case part Another core member having the same shape as the core member is housed in a space formed by the annular housing portion below and the annular housing portion of the lower core case part .

(When equipped with multiple intermediate core case parts)
Here, in the case where a plurality of intermediate core case parts are provided, each of the core case parts is connected and fixed by a connecting member, and the upper intermediate core case part is positioned below the upper intermediate core case part and the lower intermediate core case part. A core member and another core member having the same shape as that of another core member are stored in a space formed by the annular storage portion.

(Number of intermediate core case parts)
Further, the number of intermediate core case components stacked is the number obtained by subtracting 1 from the number of steps of the core member to be accommodated.

(Structure corresponding to the number of coil phases)
The upper core case parts, the number of ridges with intermediate core case part and the lower core case parts of the slit groove, and the number of connection rib of the connecting member is a line number of windings provided on the core case.

(Coil partition wall around the core case)
In the upper core case part , the intermediate core case part, and the lower core case part , a coil partition wall is formed in the outer peripheral axis direction opposite to the protruding portion formed in the cylindrical hole.

(Basic effect)
In the core case structure according to the present invention, an annular storage portion is formed on one side coaxially with a cylindrical hole, and a protrusion having slit grooves divided into a plurality of locations on the inner periphery of the cylindrical hole is formed in an axial direction. The upper core case part is formed, and an annular storage part is opened on both sides coaxially with the cylindrical hole and formed back to back, and the ridge part having slit grooves divided into a plurality of locations on the inner periphery of the cylindrical hole is axial. One or a plurality of intermediate core case parts formed on the inner side of the cylindrical hole, and an annular storage portion that is coaxial with the cylindrical hole is formed on one side opposite to the annular storage portion of the upper core case. Corresponding to the slits of the lower core case part, the upper core case part, one or more intermediate core case parts, and the lower core case part in which the ridges having slit grooves divided into parts are formed in the axial direction The mating ribs are arranged radially and each core A connecting member that is connected and fixed by fitting fitting ribs into slit grooves of a plurality of protrusions that are continuously provided in the axial direction of the cylindrical hole of each core case component in a state where the stack is axially stacked. For example, when preparing three types of core case structures in which the core member has one stage, the core member has two stages, or the core member is made of amorphous, nine types of core case parts have been conventionally required. In the present invention, the upper core case part, the lower core case part, the intermediate core case part, and five kinds of core case parts composed of two kinds of connecting members having different heights can be reduced. The number of molds used in the manufacturing can be reduced, and the manufacture and management of the core case parts are simple and easy because the number of parts is small, and the manufacturing cost can be reduced.

  Further, the increase in the number of steps of the core member can be dealt with simply and easily by increasing the number of intermediate core case parts to be used and preparing a connecting member having a height corresponding to the number of steps.

  Moreover, even when storing a plurality of stages of amorphous core members that require a structure in which a space is provided for each core member, the space for storing the core members one by one can be simplified by stacking intermediate core case parts. It is not necessary to produce a core case for each amorphous core member, and the types of core case components can be reduced.

(Effects of the cross-sectional shape of the core storage)
In addition, the annular storage portion formed in the upper core case part has a U-shaped cross-sectional shape that opens downward, and the annular storage part that is open on both sides of the intermediate core case part and formed back to back has an H-shaped cross section. Since the annular housing formed in the lower core case part has a U-shaped cross-sectional shape opened upward, the upper core case part and the lower core case part are the same as the conventional product, The intermediate core case part can be provided with sufficient strength because the cross-sectional shape of the annular storage portion is H-shaped.

(Effects due to the size of the core storage)
Further, the depth of the annular storage portion of the upper core case component, the intermediate core case component and the lower core case component is the same, and the combined depth of the annular storage portions facing each other in the state where the respective core case components are laminated is Since the depth corresponds to the thickness of the core member to be stored, an independent storage space can be easily realized for each core member by stacking the upper core case component, the intermediate core case component, and the lower core case component. .

(Effects of structure corresponding to the number of coil phases)
Further, the number of protrusions having slit grooves of the upper core case part, the intermediate core case part, and the lower core case part and the number of fitting ribs of the connecting member are the number of windings provided in the core case. Furthermore, since the coil partition wall is formed in the outer peripheral axial direction opposite to the protrusion formed in the cylindrical hole of each core case part, for single-phase 2-wire use, for 3-phase 3-wire use, for 3-phase 4-wire use, etc. The core case structure corresponding to the above can be manufactured with a few types of core case parts, and the manufacturing and management become easy, and the manufacturing cost can be reduced.

An explanatory view showing an embodiment of a core case in which a core member is housed in two stages in a three-phase three-wire system Explanatory drawing which showed embodiment of Drawing 1 in the section Explanatory drawing which showed the embodiment of the core case by which the core member was stored in three steps by a three-phase three-wire system in section Explanatory drawing which showed embodiment of the core case by which the core member was accommodated in two steps | paragraphs by the single phase two-wire system An explanatory view showing an embodiment of a core case in which a core member is housed in two stages in a three-phase four-wire system Explanatory drawing showing a conventional core case in which a core member is housed in one stage in a three-phase three-wire system Explanatory drawing showing a conventional core case in which the core member is housed in two stages in a three-phase three-wire system Explanatory drawing showing a conventional core case in which a three-phase three-wire amorphous core member is housed in two stages

[Three-phase three-wire core case]
FIG. 1 is an explanatory view showing an embodiment of a core case in which a core member is housed in two stages with a three-phase three-wire system. FIG. 1 (A) shows an appearance in an assembled state, and FIG. FIG. 1C shows a choke coil manufactured by winding a coil around a core case. FIG. 2 is an explanatory view showing the embodiment of FIG. 1 in cross section. FIG. 2A shows a cross section in an assembled state, and FIG. 2B shows a cross section in an assembled and disassembled state. 2 is a cross-sectional view taken along line XX in FIG.

(Core case components)
As shown in FIGS. 1 and 2, the core case 10 </ b> A of the present embodiment is composed of four types of parts including an upper core case part 12, a lower core case part 14, an intermediate core case part 16, and a connecting member 18. Each is manufactured by injection molding of a synthetic resin using a mold.

(Upper core case part)
The upper core case component 12 is formed with a cylindrical hole 12a in the center, an annular storage portion 12b that is coaxial with the cylindrical hole 12a and has a U-shaped cross-section and opens downward, and has an inner circumference 3 of the cylindrical hole 12a. A protruding portion 12c having slit grooves 12d divided into portions is formed in the axial direction, and a coil partition wall 12e is formed on the outer peripheral side thereof.

  The upper core case component 12 is the same as the conventional upper core case component 102 shown in FIG.

(Lower core case parts)
The lower core case component 14 is formed with a cylindrical hole 14a in the center, an annular storage portion 14b having a U-shaped cross section coaxially with the cylindrical hole 14a and formed on the upper side. A protruding portion 14c having slit grooves 14d divided into portions is formed in the axial direction, and a coil partition wall 14e is formed on the outer peripheral side thereof.

  The lower core case component 14 is the same as the conventional lower core case component 104 shown in FIG.

(Intermediate core case parts)
The intermediate core case component 16 has two annular storage portions 16b that are coaxial with the cylindrical hole 16a and are formed back-to-back on both sides, and the annular storage portion 16b has an H-shaped cross-sectional shape. Strength is secured. On the inner periphery of the cylindrical hole 16a of the intermediate core case component 16, a protruding portion 16c having slit grooves 16d divided into three portions is formed in the axial direction, and a coil partition wall 16e is formed outside thereof.

(Connecting member)
The coupling member 18 has three fitting ribs 18a arranged radially, and the upper core case component 12, the intermediate core case component 16, and the lower core case component 14 are stacked, and the slit grooves 12d, The upper core case part 12, the intermediate core case part 16, and the lower core case part 14 are connected and fixed by inserting and fitting the fitting ribs 18a into 16d and 14d from the upper side, thereby completing the core case 10A. .

  When the upper core case component 12, the intermediate core case component 16, and the lower core case component 14 are stacked and fixed by the connecting member 18, the annular storage portion 12 b of the upper core case component 12 and the intermediate core case component 16 are connected. The core member 20 is housed between the upper annular housing portion 16 b and another core is disposed between the lower annular housing portion 16 b of the intermediate core case component 16 and the annular housing portion 14 b of the lower core case component 14. By storing the member 20, the core member 20 is stored in two stages.

(Dimensions of the annular housing)
The annular storage portions 12b, 16b, 14b formed in the upper core case component 12, the intermediate core case component 16, and the lower core case component 14 have the same depth, and are opposed to each other in a state of being connected and fixed by the connecting member 18. The combined depth of the storage portions 12d, 16d or the annular storage portions 16d, 14d is formed to be a predetermined depth corresponding to the thickness of the core member 20 to be stored.

(Core member)
The material of the core member 20 housed in the core case 10A may be made of ferrite or amorphous. When ferrite is used as the core member 20, the spacer 112 is disposed between the core members 108 in the conventional structure shown in FIG. 7, but in this embodiment, the annular shape opened on both sides of the intermediate core case component 16. The back-to-back portion of the storage portion 16b functions as a spacer and does not need to be prepared as a separate part.

  Further, when an amorphous material is used as the core member 20, two sets of core case parts 116 are prepared for each core member 122 in the conventional structure shown in FIG. 8 in order to secure an independent storage space for each core member. However, in this embodiment, by connecting and fixing the upper core case part 12, the intermediate core case part 16, and the lower core case part 14 in a stacked state by the connecting member 18, The core storage space separated into two places is formed, and it is not necessary to prepare two sets of core case parts for each core member.

(choke coil)
As shown in FIG. 1C, the core case 10A having such a structure is divided into three portions partitioned by the protruding portions 12c, 16c, 14c and the coil partition walls 12e, 16e, 14e of the core case 10A. A choke coil is produced by winding a conducting wire 22 that is a coil of each phase of a three-phase alternating current around the core case part.

(Advantages of this embodiment)
When realizing the structure of the conventional core case 100B, 100C of the three-phase three-wire system shown in FIGS. 7 and 8, conventionally, eight types of core case parts are required. In the present embodiment, This can be realized with four types of core case components including the upper core case component 12, the intermediate core case component 16, the lower core case component 14, and the connecting member 18, and the number of necessary component parts is reduced to half. The cost of molds can be reduced, and the labor for manufacturing parts can be reduced.

[Embodiment of Coil Case with Increased Number of Core Stages]
FIG. 3 is an explanatory view showing a cross-section of an embodiment of a core case in which a core member is housed in three stages in a three-phase three-wire system. FIG. 3 (A) shows a cross-section in an assembled state, and FIG. ) Shows a cross section of the assembled and disassembled state.

  As shown in FIG. 3, the core case 10 </ b> B of the present embodiment accommodates the core member 20 in three stages, so that the upper core case component 12, the lower core case component 14, the two intermediate core case components 16, and the connection It is composed of four types of parts composed of members 24, and each is manufactured by injection molding of synthetic resin using a mold.

  Here, the upper core case component 12, the lower core case component 14, and the intermediate core case component 16 are the same as the core case 10A that houses the core member 20 shown in FIGS. 1 and 2 in two stages. The connecting member 24 of the present embodiment is different from the connecting member 18 shown in FIGS. 1 and 2 in that the connecting member 24 is increased by an amount corresponding to an increase of the core member 20 by one step.

  As described above, when the number of steps of the core member 20 is increased, the number of intermediate core case parts 16 is increased in accordance with the number of steps, and the connecting member 24 is increased by the amount of the added intermediate core case 16. By preparing a thing, it can respond easily and easily to the increase in the number of steps of the core member 20.

[Single-phase two-wire core case]
FIG. 4 is an explanatory view showing an embodiment of a core case in which the core member is housed in two stages with a single-phase two-wire system.

  As shown in FIG. 4, the core case 10 </ b> C of the present embodiment includes an upper core case component 26, a lower core case component 28, an intermediate core case component 16 </ b> C, and a connecting member 30 in order to store the core member in two stages. It consists of four types of parts, each manufactured by injection molding of synthetic resin using a mold.

  The annular storage portions of the upper core case component 26, the intermediate core case component 16C, and the lower core case component 28 are the same as the annular storage portions 12b, 16b, and 14b of the embodiment of FIGS. Corresponding to the linear type, for example, as shown in the upper core case component 26, protrusions 26c having slit grooves are formed at two locations on the inner periphery of the cylindrical hole 26a. The same applies to the lower core case component 28.

  Further, the connecting member 30 is a single plate member corresponding to the slit groove of the opposed protruding portion 26c.

  Even in the single-phase two-wire core case 10C of the present embodiment, the structure in which the core member is accommodated in two stages is the upper core case component 26, the lower core case component 28, the intermediate core case component 16C, and the connecting member. It can be composed of four types of 30 parts.

  As shown in FIG. 3, when the number of steps of the core member is increased, the intermediate core case part 16C is increased by one, and the connecting member 30 having a height corresponding to the increase in the core member is set to another mold. Any core material can be handled easily and easily.

[3-phase 4-wire core case]
FIG. 5 is an explanatory view showing an embodiment of a core case of a three-phase four-wire system in which core members are housed in two stages.

  As shown in FIG. 5, the core case 10 </ b> D of the present embodiment includes an upper core case part 32, a lower core case part 34, an intermediate core case part 16 </ b> D, and a connecting member 36 in order to store the core members in two stages. It consists of four types of parts, each manufactured by injection molding of synthetic resin using a mold.

  The annular storage portions of the upper core case component 32, the intermediate core case component 16D, and the lower core case component 34 are the same as the annular storage portions 12b, 16b, and 14b of the embodiment of FIGS. Corresponding to the linear type, for example, as shown in the upper core case part 32, protrusions 32c having slit grooves are formed at four locations on the inner periphery of the cylindrical hole 32a. The same applies to the lower core case component 34.

  In addition, the connecting member 36 radially forms four fitting ribs 36a corresponding to the slit grooves formed at four locations of the cylindrical hole 32a.

  Even in the three-phase four-wire core case 10D of the present embodiment, the structure in which the core member is accommodated in two stages is the upper core case part 32, the lower core case part 34, the intermediate core case part 16D, and the connecting member. It can be composed of four types of parts consisting of 36.

  As shown in FIG. 3, when the number of steps of the core member is increased, the intermediate core case part 16D is increased by one, and the connecting member 36 having a height corresponding to the increase in the core member is set to another mold. Any core material can be handled easily and easily.

[Modification of the present invention]
The present invention is not limited to the above-described embodiment, and includes an appropriate core case structure corresponding to the number of AC phases to be used, the number of windings, and the number of stages of core members.

  Further, the present invention is not limited to a core case used for a choke coil such as a noise filter, but a core case used for a choke coil for an appropriate purpose.

  The present invention includes appropriate modifications without impairing the object and advantages thereof, and is not limited by the numerical values shown in the above embodiments.

10A, 10B, 10C, 10D: Core cases 12, 26, 32: Upper core case parts 12a, 14a, 16a, 26a, 32a: Cylindrical holes 12b, 14b, 16b: Annular storage portions 12c, 14c, 16c, 26c, 32c : Protrusions 12d, 14d, 16d: slit grooves 12e, 14e , 16e : coil partition walls 14, 28, 34: lower core case parts 16, 16C, 16D: intermediate core case parts 18, 24, 30, 36: Connecting member 18a: fitting rib 20: core member 22: conducting wire

Claims (5)

The upper core is formed in a U-shaped cross-sectional shape in which an annular storage portion is opened downward coaxially with the cylindrical hole, and the protruding portion having slit grooves is formed in the axial direction divided into a plurality of locations on the inner periphery of the cylindrical hole. Case parts,
An upper annular storage portion and a lower annular storage portion that are coaxial with the cylindrical hole are formed in an H-shaped cross-sectional shape having an opening in the vertical direction, and the ridge portion has slit grooves divided into a plurality of locations on the inner periphery of the cylindrical hole. One or more intermediate core case parts formed in the axial direction;
An annular storage portion coaxially with the cylindrical hole is formed in a U-shaped cross-sectional shape with an upward opening opposite to the annular storage portion of the upper core case part , and is divided into a plurality of slit grooves on the inner periphery of the cylindrical hole. A lower core case component in which a ridge portion having an axial direction is formed;
The fitting ribs corresponding to the slit grooves of the upper core case part, the one or more intermediate core case parts, and the lower core case part are radially arranged, and the core case parts are stacked in the axial direction. wherein by the connection rib is fitted to Rukoto the slit grooves of the plurality of projecting portions provided continuously in the axial direction of the cylinder bore of the core case part in a state, connecting to connecting and fixing the respective core case parts A member,
With
The depths of the annular storage portions of the core case components are the same, and the combined depth of the annular storage portions facing each other when the core case components are stacked is the thickness of the core member to be stored. Is the depth corresponding to
With each core case component being connected and fixed by the connecting member, the core member is stored in a space formed by the annular storage portion of the upper core case component and the annular storage portion above the intermediate core case component. A core case in which another core member having the same shape as the core member is housed in a space formed by the annular housing portion below the intermediate core case component and the annular housing portion of the lower core case component. Construction.
2. The core case structure according to claim 1, wherein when the plurality of intermediate core case parts are provided, each of the core case parts is connected and fixed by the connection member, and the lower part of the upper intermediate core case part is below. The other core member having the same shape as the core member and the another core member is housed in a space formed by the annular housing portion and the annular housing portion above the lower intermediate core case part. Case structure.
3. The core case structure according to claim 1, wherein the number of stacked intermediate core case components is a number obtained by subtracting 1 from the number of steps of the core member to be accommodated.
In the core case structure according to any one of claims 1 to 3, wherein the upper core case parts, the number of protrusions having the intermediate core case part and the slit groove of the lower core case part, and the the number of connection rib coupling member, core case structure which is a line number of windings provided on the core case.
In the core case structure according to claim 4, wherein the upper core case part, wherein the intermediate core case part, and the lower core case part, the relative the outer peripheral shaft direction ridges formed in the cylindrical bore A core case structure in which a coil partition wall is formed.

Images