JPH02288310A - Flat coil - Google Patents

Abstract

PURPOSE:To obtain a thin and small-sized transformer which eliminates the disorder of winding, which is easy for manufacture, and is suitable for mass production by forming two ring parts into S-form out of a thin-plate conductor and folding them double with interposing an insulating material in a manner that those two ring parts overlap each other. CONSTITUTION:Two rings parts 1a and 1b are formed by folding them double to overlap each other. When the ring parts 1a and 1b are overlapped together, an insulating material 3 is interposed between them. At this time, as a flat coil is composed of laminated plural or a single flat coil unit 4 equivalent to two rolls of wound coils, a flat coil which is wound a desired time can be made easily by varying the number of lamination into a desired number. Thus, the transformer in which the disorder of winding is eliminated and which is easy for manufacture, and furthermore because the flat coil is thin-film form, which is thin and small-sized transformer can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a conventional winding of, for example, a high frequency transformer.

(Prior Art) A conventional transformer of this type is formed by winding an insulated wire around a ferrite core.

(Problem to be solved by the invention) However, conventional transformers have the following problems.

(2) When insulated wires are wound overlappingly around a ferrite core, the insulated wires tend to be wound in disorder, and if the windings are disordered, the magnetic resistance of the high-frequency transformer increases.

■It takes time to wind the insulated wire so that it does not become disordered, resulting in high costs.

■Since it involves wrapping insulated wire, the external size is large and it is difficult to make it particularly thin.This takes up space for mounting, making it difficult to meet the demands for miniaturization of electronic devices.

(2) As the number of turns of the insulated wire increases, the ratio of the insulating film to the conductor of the entire coil increases, and gaps are created between the insulated wires, resulting in a lower current density.

(Objective of the Invention) An object of the present invention is to provide a flat coil that has no winding disorder, is easy to manufacture, is suitable for mass production, can obtain a small and thin transformer, and has a high current density.

(Means for solving problems) A flat coil according to claim 1 of the present invention is as follows.

As shown in Fig. 1, the two ring parts 1a and 1b are the thin plate conductors 2.
The ring portions la and 1b are folded in half so as to overlap with each other via the insulating material 3 to form a flat coil unit 4 corresponding to two turns of the winding coil. The unit 4 is constructed by a single unit or a plurality of stacked units 4 that are electrically connected in series.

A second flat coil of the present invention includes a plurality of laminated flat coils at the respective terminal ends of the two ring portions 1a and 1b in the first flat coil unit 4 as shown in FIG. Connecting terminals 5a and 5b to which the coil 4 is electrically connected are molded.

(Function) In the flat coil of the first claim of the present invention, the flat coil unit 4 for two turns of the winding coil is constructed singly or by laminating a plurality of flat coil units. A flat coil with the desired number of turns can be easily made.

Further, in the flat coil according to the second aspect of the present invention, connection terminals 5a and 5 are provided at both end portions of the S-shaped ring portions 1a and 1b.
b is formed, the units 4 can be electrically connected by simply stacking a plurality of flat coil units 4 and tightening the connecting terminals 5a and 5b with screws, etc.
A flat coil with the desired number of turns can be easily obtained.

(Example) Figures 1 to 3 show an example of the flat coil of the present invention. La and 1b shown in these figures are rings formed approximately in an annular shape and connected in an S-shape. 5a and 5b are contact kc terminals formed at the terminal ends of the ring parts 1a and 1b. These are patterned by integrally molding the thin plate conductor 2 by punching or etching.

For the thin plate conductor 2, a highly conductive thin plate such as copper foil is used. This thin plate conductor 2 has a thickness of 10 μm to several hundred μm.
A material of about m can be used. In this case, 18 μm to 35 μm
It is easier to pattern a thin conductor 2 by etching a thin conductor 2 having a diameter of about 100 .mu.m, and to pattern a thin conductor 2 by directly punching a copper foil.

4 in Figure 1 is a flat coil unit.

This is formed by folding the two ring portions 1a and 1b in half and overlapping each other at the position of the imaginary line in FIG. 1a as shown in FIG. 1c. This flat coil unit 4 corresponds to two turns of a conventional wire-wound coil.

When the ring parts 1a and 1b are overlapped, an insulating material 3 is interposed between the ring parts 1a and 1b.

The insulating material 3 is formed by cutting or punching a film material such as PET, Pl, or Teflon, or an insulating plate material such as paper phenol, bake, or glass epoxy.

Various shapes are possible for this insulating material 3, but for example, the one shown in FIG. 1 has overlapping ring portions 1a.

One ring part 1a with the same shape as Ib.

The entire surface of Ib is insulated.

FIG. 2 is an exploded view of a case where a plurality of flat coil units 4 are laminated to make a flat coil with a plurality of turns. It is formed by laminating the material 6 on both sides. This laminated insulating material 6 has a ring portion 1a as shown in FIG.

A connecting terminal 5a is attached to one side of an insulating base 6b having the same shape as 1b.
Insulating protrusions 6a having the same shape as 5b are protruded, and the insulating protrusions 6a are used by turning them over alternately and changing the position of the insulating protrusions 6a from left to right.

The flat cable unit 4 is stacked as a result of this.
Of the connecting terminals 5a and 5b, the connecting terminals 5a and 5a, or 5b and 5b, which are not insulated by the insulating protrusion 6a, are electrically connected as shown by the imaginary lines in FIG. 2 to form a flat coil with a desired number of turns. So that you can get something.

Fig. 3a is an exploded view of the flat coil constituting the transformer shown in Fig. 3A. A stack of two flat coil units 4 is used as the primary coil N1, which has four turns per turn, and the secondary coil N1 has four turns per turn. A single flat coil unit 4 is used as the coil N2, and a stack of three flat coil units 4 is used as the tertiary coil N having six turns per turn.

In this case, each coil N1. An isolation insulating material 7 is sandwiched and laminated between Nz and N1 to insulate them. As shown in FIG. 3, this isolation insulating material 7 has the same planar shape as when the flat coil units 4 are stacked with the connecting terminals 5a and 5b in opposite directions, that is, a doughnut-shaped insulating base material 7b. Four insulating protrusions 7a are provided protruding from the outer periphery.

Also these flat coils N2, N2, N.

is assembled into a case 9 provided with a ferrite core 8 as shown in FIG. 3 to form a transformer.
The figure shows another embodiment of the flat coil unit 4 of the present invention.In these embodiments, instead of the insulator 3 shown in Fig. 1,
An insulating layer is formed on the thin plate conductor 2 in advance.

In the flat coil unit 4 shown in FIGS. 4a and 4b, an adhesive surface insulating layer 11a is formed on the surface of an S-shaped thin plate conductor 2, and a back insulating layer 12a is coated on the back surface of the conductor 2. It is something.

This surface insulating layer 11a is formed on a portion of the surface of the thin plate conductor 2 other than the terminals 5a and 5b so that the connection terminals 5a and 5b are exposed (not insulated), and a female pattern paper 13 is formed on the outside thereof. It is pasted.

The back insulating layer 12a is formed on the entire back surface of the thin plate conductor 2, including the terminals 5a and 5b.

This thin plate conductor 2 is valley-folded at the position of the imaginary line in Fig. 4a,
When the female pattern paper 13 is peeled off and the front insulating layers 11a are adhered to each other, a flat coil unit 4 is obtained in which the back insulating layer 12a is on the outside as shown in C1d of the figure.

In the flat coil unit 4 shown in FIGS. 5a and 5b, a surface insulating layer 11b is formed on the entire surface of the S-shaped thin plate conductor 2, including connection terminals 5a and 5b, and a surface insulation layer 11b is formed on the entire surface of the S-shaped thin plate conductor 2, and the connection terminal is formed on the back surface of the conductor 2. A back insulating layer 12b is provided on the entire surface other than the terminals 5a and 5b.
is formed. Note that the surface insulating layer 1
This thin plate conductor 2, on which the female pattern I3 is attached to 1b, is valley-folded at the position of the imaginary line in Fig. 5a,
By peeling off the fi pattern paper 13 and adhering the surface insulating layers 11a to each other, the flat coil unit 4 shown in c and d of the figure can be obtained.

The flat coil unit 4 shown in FIG. 4 obtained as described above and the flat coil unit 4 shown in FIG.
When laminated alternately as shown in the figure, the upper and lower connection terminals 5a, 5a, and 5 on which no insulating layer is formed, as shown by the imaginary line in the figure.
b and 5b are connected to form a flat coil corresponding to a plurality of turns (effects of the invention) The flat coil of the present invention has the following effects.

■ Flat coils can be made by simply stacking flat coil units 4, so there is no winding collapse like in conventional wire-wound coils. A small transformer can be obtained.

(2) By simply changing the number of layers in the flat coil unit 4, a flat coil with the desired number of turns can be easily produced.

(2) Since the insulating material 3 is also a thin film, when the flat coil units 4 are stacked, it is difficult to form gaps between the units, and the ratio of the insulating material 3 to the thin plate conductor 2 is small.
Therefore, a transformer with high current density and low magnetic resistance can be obtained.

■Connecting terminals 5a and 5b are formed at each end of the S-shaped ring portions 1a and 1b of the thin plate conductor 2, so tighten the connecting terminals 5a and 5b of the stacked flat coil unit 4 with screws, etc. It becomes possible to easily electrically connect each unit 4 with just the above. Furthermore, when wiring to the outside, connecting wires can be connected to the same terminals 5a and 5b, making the wiring work easier.

(2) If an insulating layer is formed on the thin plate conductor 2 in advance as shown in FIGS. 4 and 5, there will be no need to insert the insulating materials 3, 6, etc. one by one, and the work efficiency will be further improved.

[Brief explanation of drawings]

Fig. 1a is a plan view showing an example of the thin plate conductor in the flat coil of the present invention, the same figure is an explanatory diagram of bending the same thin plate conductor, and Fig. 1 C is a flat coil unit obtained by bending the same thin plate conductor. Figure 2 is an exploded diagram of a flat coil obtained by laminating the same flat coil unit, Figure 3 is an exploded diagram of a transformer using the same flat coil, Figures 4 and 5 are This figure shows other embodiments of the thin plate conductor in the flat coil of the present invention, and in these figures, a is a plan view thereof, a is a front view of the same figure, and a is a front view of the same figure, and a is a front view of the same figure.
is a plan view of the flat coil unit formed by figure a, figure d is a front view of figure C, figure 6 is figure 4 d,
FIG. 5 is an explanatory diagram showing the stacking of the flat coil unit of FIG. 5d. la, 1b are ring parts 2, thin plate conductors 3, insulators 4, flat coil units 5a, 5b are connection terminals

Claims (2)

[Claims] (1) The two ring parts 1a and 1b are connected to S by the thin plate conductor 2.
The ring portions 1a and 1b are folded in half so as to overlap with each other via the insulating material 3 to form a flat coil unit 4 corresponding to two turns of the winding coil, and the coil unit 4 is made into a single unit. A flat coil characterized in that it is constructed by stacking or a plurality of stacked units 4 electrically connected in series. (2) A claim characterized in that connection terminals 5a and 5b to which a plurality of laminated flat coils 4 are electrically connected are formed at the respective terminal ends of the two ring parts 1a and 1b. The first flat coil.