JP6592209B2 - Resin case for inductance element and inductance element - Google Patents

Description

  The present invention relates to a resin case for an inductance element and an inductance element accommodated in the resin case.

  In recent years, with the progress of downsizing, higher frequency, and higher current of electric or electronic devices, similar measures are required for inductance elements. However, among the magnetic cores constituting the inductance element, the material properties themselves have reached the limit in the current mainstream ferrite cores, and new materials are being sought. New materials, such as Sendust and amorphous foil strips, have been replaced by ferrite materials, but only a few moves. Amorphous powder materials with excellent magnetic properties have also appeared, but their moldability is poor compared to conventional materials and are not in widespread use.

  FIG. 10 shows a conventional inductance element composed of at least two U-shaped magnetic cores or UU-shaped magnetic cores and a coil wound around at least one portion of the magnetic core. FIG. 10 shows an inductance element having a coil on a UU-shaped core. FIG. 10 (a) is a plan view and FIG. 10 (b) is a cross-sectional view taken along line AA.

  The inductance element 13 shown in FIG. 10 has the leg portions 15 of the UU-shaped magnetic core 14 in contact with each other, and the magnetic core 14 is accommodated in the resin case 16. In addition, the coils 17 are disposed at two locations on the leg portion 15. The resin case 16 is obtained by being divided into four parts, that is, an upper surface 16a on the upper surface in plan view and 16b on the back surface, 16c on the lower surface in plan view and 16d on the back surface, and fixing the contact surfaces to each other. Further, the coil 17 is often incorporated when a core is fixed with a coil component wound in advance. FIG. 11 is a resin case of a U-shaped magnetic core, FIG. 11 (a) is a plan view, FIG. 11 (b) is a front view, and FIG. 11 (c) is a back view. The resin case 16 'has a top 16'a and a back surface 16'b in plan view.

  In the case of a U-shaped magnetic core in which soft magnetic plates such as ordinary amorphous foil strips are laminated, the outer periphery of the cores is constrained by a metal band or the like. However, when the coil components are incorporated together, the band restraint process tends to be complicated, and automation is difficult. In addition, when a powder magnetic core formed from a powdered magnetic material is fixed with a metal band, a high crushing strength and a low rattra value are required, and the application itself of this method is limited. Further, even when not fixed with a metal band or the like, a jig for fixing the U-shaped magnetic cores with an adhesive while positioning is required, and the assembly work is complicated.

  As a reactor using a split magnetic core, the laminated core is arranged in a square shape, and the circumference of the laminated core that constitutes a side that is arranged orthogonally to each outer laminated core via an insulating spacer for gap formation And an insulating cylindrical bobbin provided with a laminated core constituting the above-mentioned side, and the laminated core provided in the bobbin is divided into two in the axial direction. A reactor is known in which a partition portion for forming a gap between these divided cores is provided integrally with an inner wall portion of the bobbin (Patent Document 1). In addition, a plurality of magnetic first cores are connected via at least one or more gaps to form a core unit, and the two core units are arranged to face each other, between the ends of the two core units. The second core having magnetism is arranged opposite to each other with a predetermined distance therebetween, so that a substantially circular reactor core is formed in a plan view, and the positioning posture of the first core constituting the core unit and 2 There is known a reactor that includes a fixing member that holds and fixes the positioning posture of two second cores, and the fixing member is fixed to a case via an elastic body (Patent Document 2).

JP 2006-202922 A JP 2010-27692 A

  However, in assembling the divided resin cases also in each of the above patent documents, it is difficult to position the contact surface, the management of the core gap is insufficient, and the assembly work is complicated. there were. Moreover, when the shape of the divided | segmented resin case differs, a metal mold | die is needed for every shape.

  The present invention has been made to cope with such a problem. In assembling the inductance element, the resin case contact surface can be easily positioned, and the core gap can be easily managed. It is an object of the present invention to provide a resin case for an inductance element that can facilitate the above and an inductance element accommodated in the resin case.

  The resin case for an inductance element of the present invention is a resin case that is used for an inductance element having a coil around a magnetic core and accommodates the magnetic core. The resin case is an assembly of parts divided into a plurality of parts. And at least two of the divided parts have the same shape. In addition, complementary irregularities are formed on the end surfaces where the divided parts abut against each other. In particular, the complementary irregularities are divided into shapes that fit each other. Further, the shapes that are fitted to each other have a function of preventing disconnection after fitting.

  The resin case for an inductance element of the present invention is characterized in that it can accommodate at least one magnetic core selected from a U-shaped magnetic core, a UU-shaped magnetic core, a UR-shaped magnetic core, and an I-shaped magnetic core. Further, the resin case is characterized in that the resin case is provided with an opening having a magnetic core removal prevention portion on the end surface in the coil axial direction of the coil disposed in the resin case. The resin case is characterized in that a through hole or a recess is provided at a predetermined position of the resin case at a position not in contact with the magnetic core.

  The inductance element of the present invention is characterized in that a coil is provided around the magnetic core accommodated in the resin case of the present invention.

The resin case for an inductance element according to the present invention is an assembly of parts obtained by dividing the resin case into a plurality of parts, and at least two of the divided parts have the same shape. Can be reduced. In particular, a single mold can be obtained by making all the divided parts have the same shape.
Moreover, since the complementary unevenness | corrugation is formed in the end surface where the divided parts contact | abut, this unevenness | corrugation can be provided and it can be used as a guide for positioning. As a result, the assembly can be easily performed, and particularly when a compressed magnetic core formed from a powdered magnetic material is used, it can be easily used regardless of the mechanical properties such as the strength of the core.
Moreover, the handling at the time of conveyance becomes easy by providing a retaining function to the unevenness.

Since the two insulating cases that contain one U-shaped magnetic core can be formed into the same shape by making the concave and convex portions provided on the abutting end faces to be fitted to each other, the assemblability is improved. Further, since a single mold can be used, productivity can be increased and cost can be reduced. Further, positive cooling can be achieved by providing an opening in a part of the insulating case and bringing the core and the cooling case into contact with each other. The inductor can be positioned by providing a recess in the case, and the inductor can be positioned or fastened together with a cooling lid by providing a through hole.
Other than the combination of two U-shaped magnetic cores, U-shaped magnetic core and I-shaped magnetic core, two UR-shaped magnetic cores, UR-shaped magnetic core and I-shaped magnetic core, E-shaped magnetic core and I-shaped magnetic core, etc. Applicable.

It is a figure which shows the resin case for accommodating a U-shaped magnetic core. It is a figure explaining the combination method of a resin case. It is a figure which shows the example in case a concave shape turns into a through-hole. This is an example where there is no gap or a small gap. It is a figure explaining the combination method of the resin case of FIG. It is a figure which shows the example which provided the opening part in the resin case. It is a figure which shows the example which provided the shoulder part in the resin case. It is a figure which shows the example which does not need to provide a shoulder part in the resin case. It is a figure which shows the example which provided the through-hole for positioning. It is a figure which shows the inductance element which has a UU type magnetic core. It is a figure which shows the resin case of a U-shaped magnetic core.

  The resin case of this invention is related with the resin case for accommodating the magnetic core in the inductance element which has a coil around a magnetic core. FIG. 1 shows one of the divided parts when a U-shaped magnetic core is taken as an example of the magnetic core. FIG. 1A is a plan view upper plan view of a resin case for a magnetic core divided into four parts, and FIG. 1B is a front view. FIG.1 (c) is sectional drawing which shows the other example (two) of complementary uneven | corrugated shape. The U-shaped magnetic core housed in the resin case becomes an annular magnetic core in plan view by abutting the U-shaped legs. One form of the resin case divided into four is shown in FIGS. 1 (a) and 1 (b). This resin case 1 for U-shaped magnetic cores is an example in the case where the gap formed between the U-shaped magnetic cores is large enough to arrange the uneven shape.

The resin case 1 shown in FIGS. 1A and 1B protrudes from the contact surface on one surface of the contact surfaces of the axial leg portions 2 of the coils disposed on the outer periphery of the resin case. The convex shape A1 is provided, and the concave shape A2 that is recessed from the contact surface is provided on the other surface. This uneven portion is provided at a position where it can be fitted when rotated and face another resin case 1. In other words, in a plan view of the resin case 1, uneven portions that are fitted to each other at the time of assembly are provided at positions that are line symmetrical with respect to the center line 3. By combining four resin cases 1 having the same shape, a case that can accommodate an annular magnetic core in a plan view is obtained. This case is divided into four in the thickness direction of the magnetic core and the axial direction of the coil, and FIGS. 1 (a) and 1 (b) show one of them.
The two shapes shown in the cross-sectional view of FIG. 1C are examples of complementary uneven shapes different from those in FIG. In these examples, at least one of the cross-sectional shapes in the thickness direction and the axial direction in the magnetic core leg may be the shape shown in the figure, and the cross-sectional shapes in the thickness direction and the axial direction are the same shape. It may be a combination of different shapes.

A method of combining the resin cases 1 will be described with reference to FIG. 2 is a combined front view, FIG. 2 (a) shows one U-shaped core, and FIG. 2 (b) shows the other U-shaped core. FIG. 2C shows a form in which the engaging claw is provided in FIG. 2A, and FIG. 2D shows a side view thereof.
As shown in FIG. 2 (a), two cases 1a and 1b are prepared as a resin case 1 having irregularities on the legs, and magnetic cores molded into a predetermined U shape are formed on the case 1a and the case 1b. Fit. At that time, the case 1a and the case 1b are formed by overlapping the resin case 1 having the same shape, so that the convex shape A1 of the case 1a and the concave shape A2 of the case 1b are adjacent to each other, and the concave shape A2 of the case 1a and the convex shape of the case 1b. The shape A1 is adjacent to the shape.
Further, as shown in FIGS. 2 (c) and 2 (d), the case 1a and the case 1b are integrally formed by providing complementary engaging claws 18 for preventing the drop-off at least at two or more locations in the thickness direction. It is good. The concave and convex shape of the engaging claw 18 is provided at a position where it can be fitted when rotated and faced with another resin case.

  As shown in FIG. 2B, two cases 1c and 1d are prepared, and the resin case 1 is overlaid in the same manner as in FIG. The two U-shaped magnetic cores containing the magnetic cores thus obtained are faced in the coil axis direction and assembled while guiding the other convex part in one concave part, thereby obtaining an annular inductance element in plan view. Easy to get. That is, it assembles so that convex A1 of case 1a shown in Drawing 2 (a) and concave A2 of case 1c shown in Drawing 2 (b) may fit. As a result, the concave shape A2 of the case 1a shown in FIG. 2 (a) and the convex shape A1 of the case 1c shown in FIG. 2 (b) are fitted, and the convex shape A1 of the case 1b shown in FIG. The concave shape A2 of the case 1d shown in FIG. 2B is fitted, and the concave shape A2 of the case 1b shown in FIG. 2A and the convex shape A1 of the case 1d shown in FIG. To do.

  FIG. 3 shows an example in which the concave shape A2 becomes the through hole A2 '. Even in this case, similarly to the concave shape, by preparing four resin cases, it is possible to easily assemble an annular inductance element in plan view. That is, it is assembled so that the convex shape A1 'of the case 1a' shown in FIG. 3A and the through hole A2 'of the case 1c' shown in FIG. As a result, the through hole A2 ′ of the case 1a ′ shown in FIG. 3A and the convex shape A1 ′ of the case 1c ′ shown in FIG. 3B are fitted, and the case 1b ′ shown in FIG. 3B and the through hole A2 ′ of the case 1d ′ shown in FIG. 3B are fitted, and the through hole A2 ′ of the case 1b ′ shown in FIG. 3A is shown in FIG. 3B. The convex shape A1 ′ of the case 1d ′ is fitted.

  It is preferable that the convex shape, concave shape, or through-hole to be fitted to each other is provided with a function of preventing the removal after fitting. As a function of preventing the post-fitting prevention, for example, a complementary irregularity such as a curved surface or a saddle shape is provided on a surface perpendicular to the contact surface of the fitting portion.

  FIG. 4 shows an example of the resin case 4 that accommodates the U-shaped magnetic core when there is no gap on the contact surface of the leg 2 or when the gap distance is small and it is difficult to provide a recess. 4A is a plan view, FIG. 4B is a front view, and FIG. 4C is a back view. The resin case 4 is provided with a convex shape A3 and a concave shape A4 on the outer peripheral portion close to the contact surface. The boundary between the projections and depressions is preferably near the center line 5 in plan view of one leg. Further, it is desirable to round the corners of the convex shape A3 to prevent chipping during assembly. When there is a gap in the magnetic core, if the legs of the U-shaped magnetic core are divided and move freely in the insulating resin case 4, a resin plate or the like that suppresses the movement of the U-shaped magnetic core is inserted for positioning. Can do.

A method of combining the resin cases 4 will be described with reference to FIG. FIG. 5 is a combined plan view. FIG. 5A shows an upper half of the case in plan view, and FIG. 5B shows a lower half of the case.
Two cases 4a and 4b are prepared as the resin case 4 having an uneven leg portion, and magnetic cores molded into a predetermined U shape are accommodated in the case 4a and the case 4b. At that time, the case 4a and the case 4b are formed by overlapping the same resin case 4, so that the convex shape A3 of the case 4a and the concave shape A4 of the case 4b face each other, and the concave shape A4 of the case 4a and the convex shape A3 of the case 4b. And face each other.

  Similarly, two cases 4c and 4d are prepared, and the resin case 4 is overlaid in the same manner as described above. By assembling the two U-shaped magnetic cores containing the magnetic cores obtained in this way while facing the coil axis direction and guiding the other convex part in one concave part, the gap distance can be reduced from zero. An inductance element having an annular shape in plan view that can be set is easily obtained. That is, it assembles so that convex shape A3 of case 4a shown to Fig.5 (a) and concave shape A4 of case 4c shown in FIG.5 (b) may fit. As a result, the concave shape A4 of the case 4a shown in FIG. 5A and the convex shape A3 of the case 4c shown in FIG. 5B are fitted, and the convex shape A3 of the case 4b shown in FIG. The concave shape A4 of the case 4d shown in FIG. 5 (b) is fitted, and the concave shape A4 of the case 4b shown in FIG. 5 (a) and the convex shape A3 of the case 4d shown in FIG. 5 (b) are fitted. To do.

  The combination method shown in FIG. 2, FIG. 3, and FIG. 5 is a method in which four resin cases having the same shape capable of accommodating a U-shaped magnetic core are prepared and combined to obtain an annular inductance element in plan view. However, even if it is a combination of a U-shaped magnetic core and an I-shaped magnetic core, the shape of the surface where the I-shaped magnetic core abuts on the U-shaped magnetic core is made uneven as described above, so that the case for the I-shaped magnetic core Can have one mold.

  In the resin case shown in FIGS. 1 and 4, an opening for exposing and cooling the part of the magnetic core accommodated can be provided. An example in which an opening is provided is shown in FIG. 6 is an example in which an opening for cooling is provided in the resin case shown in FIG. 1, FIG. 6 (a) is a plan view, FIG. 6 (b) is a front view, and FIG. 6 (c) is a back view. It is. Note that the concave and convex portions are not shown. An opening 7 is provided at the top of the resin case 6. At this time, in order to prevent the coil from coming off in the axial direction, a part of the case is left in the direction of coming off or a shoulder portion 6a is provided.

An inductance element is obtained by housing a magnetic core in a resin case and forming a coil around the magnetic core, but a shoulder for positioning the coil can be provided in the resin case. By providing the shoulder portion, the assembly of the inductance element is facilitated.
FIG. 7 shows an example in which a shoulder portion is provided. FIG. 7A is a plan view, FIG. 7B is a front view, and FIG. 7C is a back view. The uneven portion is not shown. A shoulder portion 9 for positioning the coil can be provided on the outer periphery of the leg portion of the resin case 8. When assembling the inductance element, the coil positioning guide is not required on the cooling case or the ground plane. If the coil is up to the full size of the leg, the shoulder need not be provided. An example in that case is shown in FIG. 8A is a plan view, FIG. 8B is a front view, and FIG. 8C is a back view. The uneven portion of the resin case 10 is not shown.

  An example in which a through hole for positioning the inductance element is provided is shown in FIG. 9A is a plan view, FIG. 9B is a front view, and FIG. 9C is a back view. The uneven portion is not shown. The through hole 12 for positioning the inductance element is provided in the resin case 11 at a location that does not come into contact with the magnetic core accommodated therein, for example, near the apex angle of the quadrangular shape in plan view. A recess can be provided instead of the through-hole 12. Positioning is possible only at two diagonal points. Further, it can be fastened together with positioning at four places near the apex while positioning with a cooling lid or the like. Thereby, it can cool more actively. When not tightened together, a recess can be provided to position the inductance element.

  The inductance element of the present invention uses the resin case that is easy to position. Therefore, in addition to the combination of two U-shaped magnetic cores, the U-shaped magnetic core and I-shaped magnetic core, two UR-shaped magnetic cores, and the UR-shaped magnetic core are used. And an I-type magnetic core, and an inductance element combining an E-type magnetic core and an I-type magnetic core. In addition, since it has the functions of gap management of the magnetic core and retaining function during transportation, it can improve the assembling property of the inductance element and use a single mold, so that the productivity can be improved and the cost can be reduced. it can.

  Since the resin case for an inductance element of the present invention can be easily positioned at the time of assembly and can have a single mold, it can be applied to a wide variety of inductance elements.

DESCRIPTION OF SYMBOLS 1, 4, 6, 8, 10, 11 Resin case 2 Leg part 3, 5 Centerline 7 Opening part 9 Shoulder part 12 Through-hole 13 Inductance element 14 UU-shaped magnetic core 15 Leg part 16 Resin case 17 Coil 18 Engagement nail | claw

Claims (8)

A resin case for an inductance element that is used in an inductance element having a coil around a magnetic core and houses the magnetic core,
The resin case is an assembly of parts divided into four in the thickness direction of the magnetic core and the axial direction of the coil, and each of the divided parts is U-shaped,
The divided parts are parts divided into U-shaped legs of the divided parts having complementary irregularities, and the complementary irregularities are fitted into each other.
In the resin case, two of the divided parts are respectively a convex shape of the complementary unevenness of one part and a concave shape of the complementary unevenness of the other part in the thickness direction of the magnetic core. The resin case for an inductance element is a case in which the overlapped parts are mutually fitted by the complementary irregularities in the axial direction of the coil . The divided parts, the leg portions of the divided parts having the complementary irregularities on the end surface abutting the convex on one end surface, the concave is formed on the other The resin case for an inductance element according to claim 1. Wherein the shape to be fitted to each other, according to claim 1 or claim 2 inductance resin case element according characterized by having a function of preventing the pulling out after fitting. The resin case is U-shaped magnetic core, either UU type magnetic cores, and from the claims 1 to characterized in that the resin case to accommodate at least one of the magnetic core are selected from the UR-type magnetic core to claim 3 1 The resin case for an inductance element according to the item. The resin case, which has an opening on the end face in the axial direction of the coil, inductance element according to any one of claims 1 to characterized in that it has a detachment prevention portion of the magnetic core to claim 4 Resin case. The inductance element for a resin case according to any one of up to claims 1 to 5 which further comprising a shoulder portion comprising a positioning of said coil legs periphery of the resin case. The resin case for an inductance element according to any one of claims 1 to 6 , wherein a through hole or a concave portion is provided at a location that does not contact the magnetic core of the resin case. An inductance element comprising a coil provided around a magnetic core housed in a resin case, wherein the resin case is the resin case for an inductance element according to any one of claims 1 to 7. Inductance element characterized by being.

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