JPH03265109A - Endless iron core coil and manufacture thereof - Google Patents

Abstract

PURPOSE:To get an endless iron core coil by deforming an iron core after winding a coil on the iron core of thermoplastic resin material, and coupling both ends in endless shape magnetically, and covering it with synthetic resin. CONSTITUTION:A conductor is wound to form an annular single winding coil 1 having connections 1a and 1b. The iron core 2 of a column is let pass through the coil 1. The iron core 2 is made of synthetic resin being thermoplastic and having high permeability. The material is one where high permeability of powder magnetic material in the line of ferrite is solidified with the thermoplastic resin such as nylon, or the like as a binder. The iron core 2 is preheated to facilitate the deformation, and it is rounded in a circle, and both ends 2a and 2b are butted and stuck fast. The periphery of the iron core 2 is covered with synthetic resin 4 so as to complete it. According to this constitution, the work efficiency is excellent than the case where a toroidal winder is used. Moreover, it can be manufactured mainly by resin molding, so it can be mass-produced.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to an endless iron core coil used in high frequency noise removal coils such as power filters and RF chokes, or pulse transformers for DC-DC converters, and the like. Regarding the manufacturing method.

[Prior Art] In conventional power supply filters, choke coils for high frequency removal, and small pulse transformers, toroidal coils, in which the coil is wound around a ring-shaped endless iron core, are often used.

[Problems to be Solved by the Invention] Although toroidal winding for an endless core is wound using a toroidal winding machine, it is extremely troublesome and has poor productivity.

In particular, for conductors used in circuits with large currents, the diameter of the core is small compared to the thickness of the winding, so the bending radius of the conductor is small, making it extremely difficult to wind, and the force required to wind it is also large. .

[Means for Solving the Problems] According to the present invention, there is provided a ring-shaped single-turn coil (1) that is wound a required number of times with a required winding diameter, and a ring-shaped single-turn coil (1) that is inserted into the single-turn coil (1) and that is wound at both ends. An iron core (2) made of a thermoplastic magnetic synthetic resin material that is in close contact with each other (2a) (2b) so that they are magnetically endless, and an iron core (2) and a coil (1).
) and a synthetic resin material (4) covering the outside of the endless core coil (A).
), a step of forming an elongated linear iron core (2) made of thermoplastic magnetic synthetic resin material, a step of inserting the iron core (2) into the single-turn coil (1), and a step of inserting the iron core (2) into the single-turn coil (1). The process of rolling it into a ring shape and magnetically closely butting both ends (2a) (2b) of the iron core (2) and coil (1).
A manufacturing method of an endless iron core coil (A) consisting of a process of inserting an endless core coil (A) and covering the outside with a synthetic resin material (4), or a method of manufacturing an endless iron core (2) consisting of a step of inserting a long and thin linear iron core (2) made of a thermoplastic magnetic synthetic resin material. A process of forming, a process of winding the coil (1) around the iron core (2), a process of rolling the iron core (2) into a ring shape, and magnetically closely abutting both ends (2a) and (2b) of the iron core. The above-mentioned problem is solved by (2) and the step of inserting the coil (1) and covering the outside with the synthetic resin material (4).

[Function] After assembling the coil (1) to the iron core (2) made of thermoplastic magnetic synthetic resin material, the iron core (2) is deformed so that both ends (
By magnetically coupling 2a) and (2b) in an endless manner and coating the outer periphery with synthetic resin, an endless iron core coil (A) can be produced without using a toroidal winding machine.

[Example] Figures 1 to 4 illustrate the procedure for carrying out the method of the present invention.

As shown in Figure 1, by winding the conductive wire in a spiral shape many times in the same manner as when making a coil spring, etc., the wire is twisted the required number of times as a coil, and the connections extending from both ends of the wire are twisted. A ring-shaped single-turn coil (1) having portions (la) and (lb) is formed.

Next, as shown in Fig. 2, inside the single-turn coil (1),
Insert the cylindrical iron core (2).

The iron core (2) is made of a thermoplastic synthetic resin material with high magnetic permeability.

Such a material is, for example, a ferrite-based powder magnetic material with high magnetic permeability hardened using a thermoplastic resin nylon 6 or nylon 12 as a binder. Note that such a material is hereinafter referred to as a magnetic synthetic resin material.

Next, as shown in FIG. 3, the iron core (2) is rolled into a circle, and both ends (2a) and (2b) thereof are brought into close contact with each other.

In this process, the iron core (2) is warmed in advance to make it easy to deform, and is carried out when the iron core (2) is placed in the mold (3) in the next insert molding process. good.

The shaded area in Figure 3 is the insert molding mold (3)
This is the part that becomes.

FIG. 4 shows an endless iron core coil (A) according to the present invention, which is completed by coating and molding a synthetic resin material (4) around the outer periphery of an iron core (2) around which a single-turn coil (1) is wound.

This synthetic resin material (4) may be a non-magnetic material or the same magnetic synthetic resin material as the iron core (2). Cover the iron core (2
), the magnetic coupling between the butt ends (2a) and (2b) of the iron core (2) will be good.

FIG. 5 to FIG. 7 show an embodiment in which a flat plate-shaped iron core (2A) is used instead of the above-mentioned cylindrical iron core (2).

In this embodiment, the same parts as in FIGS. 1 to 4 are given the same reference numerals.

The single-turn coil (IA) in this embodiment is directly wound the required number of times around the flat iron core (2A), and there is no separate step of making only the single-turn coil (IA) in advance.

FIG. 6 shows the flat iron core (2A) in a rolled state.

FIG. 7 shows the finished product of FIG. 6, the outside of which is coated with resin.

Above, the single-turn coil (1) wound around the iron core (2) (2A)
) (IA) is one, but there may be a plurality of them.

In addition, the iron core (2) is rolled into a ring shape with an open mouth in advance, and the opening part, that is, both ends (2a) of the iron core (2) (
The single-turn coil (1) is passed through between 2b) and the openings at both ends (2a and 2b) are sealed by temporarily elastic deformation by applying external force when insert molding. It is also possible to close the iron core (2) and then, during insert molding in the post-process, to thermoplastically deform the iron core (2) using the heat of the resin covering the outside.

[Effects] Work efficiency is improved compared to work performed using a cotroidal wire winding machine.

Since it can be manufactured mainly by resin molding, mass production is easily possible.

[Brief explanation of drawings]

1 to 4 show an embodiment of the method for manufacturing an endless iron core coil of the present invention. FIG. 1 is a perspective view of a single-turn coil, and FIG. 2 shows an iron core in a single-turn coil. FIG. 3 is a perspective view of an iron core wound with a single-turn coil, and FIG. 4 is a partially cutaway view of an embodiment of the endless core coil of the present invention. 5 to 7 show other embodiments of the manufacturing method of the present invention, and FIG. 5 is a perspective view of a single-turn coil wound around a flat iron core. FIG. 6 is a perspective view of the flat iron core rolled up, and FIG. 7 is a partially cutaway perspective view of the finished product in which the outside of the core shown in FIG. 6 is coated with resin by insert molding. (1) (IA) Single-turn coil (2) (2A) Iron core (3
) type (4) Synthetic resin material (A) Endless iron core coil Figure 1 Figure 5 Figure 82 Figure 3 Figure 4rlA 6th v! J Figure 7

Claims (3)

[Claims] (1) A ring-shaped single-turn coil that has been wound the required number of times with the required winding diameter, and a thermoplastic that is inserted into the single-turn coil and tightly abutted so that both ends are magnetically endless. An endless iron core coil characterized by comprising an iron core made of a magnetic synthetic resin material, and a synthetic resin material covering the outside of the iron core and the coil. (2) A process of winding a linear single-turn coil, a process of forming an elongated linear iron core made of thermoplastic magnetic synthetic resin material, a process of inserting the iron core into the single-turn coil, and a process of rolling the iron core into a ring shape. A method for manufacturing an endless iron core coil, which comprises the steps of: magnetically closely butting both ends of the coil; and inserting the core and coil, and covering the outside with a synthetic resin material. (3) The process of forming an elongated linear iron core made of thermoplastic magnetic synthetic resin material, the process of winding a coil around the iron core, and the process of rolling the iron core into a ring shape and magnetically closely butting both ends of the core. , A method for manufacturing an endless iron core coil, which comprises the steps of inserting an iron core and a coil, and covering the outside with a synthetic resin material.