JPH03206605A - Choke transformer - Google Patents

Abstract

PURPOSE:To provide the polarities of coils in the same direction by a continuous winding and to obtain a choke transformer having excellent productivity and quality by inverting its winding direction with the end of winding as a starting point. CONSTITUTION:Collars 2, 3 are provided at the upper and lower ends of a spool 1 in which a core 12 is passed. A pair of guide ribs 4 for guiding the core 12 and a directional determining rib 5 are provided at the collar 2. A large part 6 is provided at the collar 3, and a plurality of guide grooves 7 of leads 11 of a coil 10B are provided. A pin terminal 8 is planted on the lower surface of the part 6 to form a bobbin 9. In the spool 1, the leads 11 are wound at the terminal 8 through the grooves 7, and a first layer coil 10B is wound. The leads of the end of a winding are wound at the other pin through the grooves 7, a second layer is reversely wound, and a coil 13 is then similarly formed. An EI-shaped core is inserted into the coil to form an air gap 14. According to the structure, winding and wiring can be automated, and a choke transformer having high performance and high reliability can be inexpensively produced by a magnetic path by three layer laminated coil and a suitable air gap.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a Chikok transformer for an inverter circuit used in various power supply equipment, video equipment, audio equipment, home appliances, industrial equipment, etc.

Conventional technology In recent years, there has been remarkable progress in inverter circuit power supply technology. In particular, requirements for choke transformers, which are the main components of inverter circuits, are severe, and low frequency band (A
In order to cope with large currents (AC 5 0/6 0 Hz) and to reduce loss and reduce the size of switching noise currents that occur in low switching frequency bands (AC 25K to 30KHz), silicon mesh is used in the magnetic core and air is inserted into the magnetic path. By providing a gap, the DC current superimposition characteristics of the inductance,
In addition to improving frequency characteristics, φ1. A coil is wound around a thick wire exceeding 0m to form a transformer. It also occurs in a high frequency band. The loss due to the skin effect of the inflow current is also large, and a cross-sectional view equivalent to the thick copper wire described above is obtained.
In order to increase the surface area of the copper wire, it is common to wind a coil using a plurality of copper wires to construct a check transformer.

The conventional check transformer is shown in Figs. 14, 15, and 1.
The one consisting of a single coil IOA with the thick line shown in Figure 8, and the one consisting of multiple copper wires with the same line cross-sectional area as the thick line shown in Figures 16, 17, and 19 in the same winding direction. It consisted of a coil IOB wound in layers. That is, an upper end flange 2 and a lower end flange 3 are provided at the upper and lower ends of a cylindrical winding frame 1 through which an iron core 12 made of magnetic material is passed through the center, and a pair of iron cores 12 are guided to the upper end flange 2. A guide rib 4 and a directional rib 5 for determining directionality are provided. The lower end flange 3 has an enlarged part 6 formed therein, and is provided with a plurality of guide grooves 7 for guiding the lead wire 11 drawn out from the coil IOA-B. The bobbin 9 is constructed by planting the bobbin 9. The lead wire 11 at the beginning of winding is wound around the winding frame 1 of the bobbin 9 through the guide groove 7 to any pin terminal 8, and the coil IOA is wound and the lead wire 11 at the end of winding is routed through the guide groove 7. Through it, wrap the wire around the other pin terminal 8 and connect by soldering. One coil IOA or different pin terminals 8
An EI type iron core 12 is attached to the coil part 13, which is composed of a plurality of coils IOB that are laminated and wound in the same winding direction.
As shown in Figures 15 and 17, you can create an air gap by making the middle leg of the E type shorter than the leg lengths on both sides, or create an air gap between the E type and the I type (not shown). The structure was such that an air gap was formed by inserting a paper gap paper.

Problems to be Solved by the Invention In such conventional structures, it is extremely difficult to rationalize and automate the winding process because thick copper wire (1.0 mm+ or more) is used, and the winding process relies on hand processes. Since it is a line process, there are serious problems in terms of production capacity and cost.

In addition, multiple laminated wound coils IO with improved performance
In the configuration according to B, the condition for automation with existing equipment is 0.
Wire diameters of 8 mm or less can be used, but stacked coil IO
The number of lead wires to be processed increases in proportion to the number of H's.

For this reason, there have been many problems such as the effectiveness of automation being greatly reduced if the man-hours for cutting the lead wires are included.

The object of the present invention is to eliminate the above-mentioned conventional drawbacks and to provide a check transformer with excellent productivity and quality.

Means for Solving the Problems In order to solve the above problems, the present invention is a method of forming a plurality of laminated coils by continuously winding a coil while reversing the winding direction starting from the end of winding of the coil. It is.

Effect: With this configuration, even though the coils are made up of continuous windings, by reversing the winding direction, the polarity of each coil becomes the same, making it possible to connect multiple coils using separate terminals. The same electrical performance as laminated winding can be obtained.

Example An embodiment of the present invention will be described below with reference to the drawings.

FIGS. 1 and 2 are a perspective view and a sectional view showing an embodiment of the present invention, and FIG. 3 is a wiring diagram. FIGS. 4 and 5 are a perspective view and a sectional view showing another embodiment of the present invention. As shown in the figure, an upper end flange 2 and a lower end flange 3 are provided at the upper and lower ends of a winding frame l through which an iron core 12 made of magnetic material passes through the center, and a guide rib 4 that guides a pair of iron cores 12 is provided on the upper end flange 2. A directional rib 5 for determining directionality is provided. The lower end flange 3 is formed with an enlarged portion 6,
A bobbin 9 is constructed by providing a plurality of guide grooves 7 for guiding the lead wire 11 drawn out from the coil 10B, and by planting a plurality of pin terminals 8 on the lower end surface of the enlarged portion 6. The lead wire 11 at the beginning of winding is wound around the winding frame 1 of the bobbin 9 through the guide groove 7 to any pin terminal 8, the first layer coil IOB is wound, and the lead wire 11 at the end of winding is wired. After winding and wiring through the guide groove 7 to another pin terminal 8, the second layer coil IOB is continuously wound in the opposite direction to the winding direction of the first layer coil IOH, and the lead-out lead at the end of winding is wound. The wire 11 is passed through the guide groove 7 and wound around another pin terminal 8 for wiring. Furthermore, the third layer coil IOB is connected to the second layer coil I.
The lead wire 11 is wound in the opposite direction to the winding direction of the OB, and the lead wire 11 at the end of the winding is passed through the guide groove 7, wrapped around another pin terminal 8, and then cut. A lead wire 1l is connected to the pin terminal 8 by soldering to form a coil portion 13. Insert the EI type iron core 12 into the above coil part, butt the E type iron core 1.
Air gap 1 by making the middle leg length of 2 shorter than the leg length at both ends.
4 will be provided. Alternatively, although not shown, a gap paper such as paper is inserted between the E type and the 1 type to form an air gap 14 to construct a choke transformer.

Figure 4. FIG. 5 shows another embodiment of the invention. An EO type iron core 12 is inserted into the coil portion 13 from the same direction, and a gap formed at the tip of the EO type iron core 12 protruding from the bobbin 9 is formed as an air gap 14 to constitute a choke transformer.

The assembled view in FIG. 6, the perspective view in FIG. 7, and the sectional view in FIG. 8 show an embodiment of the sealed choke transformer of the present invention.

As shown in the figure, two pairs of bobbin holding protrusions 16 are provided on the inner surface of a cylindrical plastic case 15 with one side open and in contact with the upper end collar 2 of the bobbin 9.
A directional convex portion 19 into which the directional lip 5 provided on the upper end collar 2 of the bobbin 9 fits is provided. In the above case 15,
After storing the coil portion 13 and filling it with a resin material (not shown), a pin terminal through hole is implanted in the lower end surface of the enlarged portion 6 formed in the bobbin 9, and a plurality of pin terminals 8 pass through the pin terminal through hole. A sealed choke transformer is constructed by inserting pin terminals 8 into a plastic bottom plate 17 having a diameter of 18 while penetrating them.

FIG. 9 shows the inflow current waveform of the choke transformer, showing a state in which a low frequency component current 20 and a switching noise current 21 are mixed. FIG. 10 shows the relationship between ACR (alternating current resistance) and air gap. Loss caused by ACR and switching noise current 21 accounts for most of the causes of temperature rise in the choke transformer. Figure l1, Figure 12
Figure 13 shows the conventional product with a single-turn coil gap of 0.5.
This figure compares the electrical performance of InIl1 and a three-layer coil according to an embodiment of the present invention using an EO type iron core.

Effects of the Invention As described above, compared to conventional choke transformers, the present invention realizes automation of winding and wiring by sequentially stacking and winding multiple coils while reversing the winding direction.
In addition to achieving a significant reduction in man-hours, by adopting a three-layer laminated coil and a magnetic path configuration with an appropriate air gap, we have achieved an increase in L and a halving of ACR by reducing the switching frequency band, resulting in high performance and reliability. The practical effects are great, such as being able to produce and supply choke transformers with high efficiencies at lower cost.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing an embodiment of the choke transformer of the present invention, FIG. 2 is a sectional view of the choke transformer, and FIG. 3 is a wiring diagram of the choke transformer. FIG. 4 is a perspective view showing another embodiment of the choke transformer of the present invention, FIG. 5 is a sectional view of the same choke transformer, and FIG. 6 is an assembled view showing an embodiment of the sealed choke transformer of the present invention. , Fig. 7 is a partially cutaway perspective view of the choke transformer, Fig. 8 is a sectional view of the choke transformer, Fig. 9 is a current waveform diagram flowing into the choke transformer, and Fig. 10 is the ACR of the choke transformer ( Fig. 11 is a characteristic diagram showing the frequency characteristics of the inductance of a conventional choke transformer and a choke transformer according to an embodiment of the present invention, and Fig. 12 shows the DC superimposition performance of the same inductance. Shown: Guide groove, 8: Bin terminal, 9: Bobbin, 10A, IOB...
Coil, 1l... Lead wire, 12...
...Iron core, 13...Coil part, 14...
... Air gap, 15 ... Case, 16
...Bobbin holding protrusion, l7...Bottom plate, l8...Bin terminal through hole.

Claims (2)

[Claims] (1) It has a cylindrical winding frame in the center for passing the magnetic material through, an upper end flange and a lower end flange are provided at the upper and lower ends of the winding frame, an enlarged part is formed in the lower end flange, and a lead wire is drawn out from the coil. A bobbin is constructed by providing a plurality of guide grooves and planting a plurality of pin terminals on the lower end surface of the enlarged portion, and a plurality of coils are placed on the winding frame of the bobbin, and the end of winding of each coil is connected to the winding frame of the bobbin. As a starting point, while alternately reversing the coil winding direction, pass the end of the winding lead wire through the guide groove and wrap it around the pin terminal, then wind it continuously and connect the lead wire winding part of the pin terminal by soldering. A choke transformer that incorporates magnetic material into the coil section. (2) From the open surface of the plastic case, which is cylindrical and has one side open and has two pairs of bobbin holding protrusions on the inner surface,
The trunks according to claim 1 are housed, filled with a resin material, and the pin terminals are inserted through a plastic bottom plate having pin terminal holes opposite to the pin terminals implanted in the bobbin. choke transformer.