JPH0473914A - Manufacture of e-shaped core - Google Patents

Abstract

PURPOSE:To enable manufacture of E-type cores of structure design that each part dimension is effectively utilized by a simple fabrication process without use of any molding equipment hard to control and troublesome to handle by molding a magnetic material into a square shape for cutting work of one square shape face into a plurality and by cutting a pair of side columns. CONSTITUTION:In a manufacture of an E-shaped core 81 having a center magnetic leg 82, a pair of side magnetic legs 83, 84 counterposed to sandwich the center magnetic leg 82, and a yoke 85 which couples one end of the center magnetic leg 82 with one end of each of the side magnetic legs 83, 84, a magnetic material is molded into a square shape having a pair of said columns 62, 63, a pair of common columns 64, 65 which couple both ends of each of the side columns 62, 63, and a center common column 66 which couples the center of the side columns 62, 63, and is subjected to cutting work so that one square shape face of the molded body 61 may be divided into a plurality; thereby, a center magnetic leg 82 is formed in the common columns 64, 65, and the side columns 62, 63 are used as the side magnetic legs 83, 84. Further, the side columns 62, 63 and the center common column 66 are cut to manufacture an E-shaped core 81.

Description

[Detailed Description of the Invention] (Industrial Application Field) This invention relates to a method for manufacturing an E-type core made of a magnetic material used for magnetic cores of transformers, choke coils, noise filters, etc. , E-type cores are manufactured by simple molding and cutting.
The present invention relates to a method for manufacturing a mold core.

(Prior Art) In recent years, there has been an increasing demand for smaller electronic devices, and in particular, there is a demand for thin and lightweight electronic devices that can be carried and used outdoors or indoors.

Therefore, there is a strong demand for smaller and lighter transformers, choke coils, noise filters, and the like used in these electronic devices.

Therefore, there is a strong demand for thinner and lighter cores made of magnetic materials used as magnetic cores in transformers, choke coils, noise filters, etc., and various proposals have been made to date. .

An E-type core is generally used as a magnetic core incorporated in the transformer, etc., and a conventional example of the E-type core will be explained with reference to FIGS. 5(a) and 5(b).

In FIG. 5(a), an E-shaped core la made of a magnetic material such as ferrite has a central magnetic leg 2 having a substantially square cross section.
A pair of first side magnetic legs 3a and second side magnetic legs 4a are arranged on both sides of a, each having a first groove 6a and a second groove 7L. One end of each of the leg 3a and the second side magnetic leg 4a is connected by a yoke portion 5a.

At this time, the other end surfaces of the central magnetic leg 2a, the first side magnetic leg 3a, and the second side magnetic leg 4a are formed on the same plane, and
In order to optimize the magnetic properties of the E-shaped core 1a, the cross-sectional area of the central magnetic leg 2a is made equal to the sum of the cross-sectional areas of the first side magnetic leg 3a and the second side magnetic leg 4a. It is formed.

When incorporating the E-type core 1a into a transformer etc., the fifth
As shown by the imaginary line in FIG. The combination is fixed using a fixing fitting (not shown) or the like.

As described above, the coil bobbin 8 is attached to the E-type core la.
When the coil bobbin 8a is fitted, the upper and lower parts of the winding of the coil bobbin 8a protrude from the upper and lower surfaces of the central magnetic leg 2a of the E-type core 1a by a width Za. It was not used effectively, and there were problems such as poor stability when mounting the transformer etc. on an electronic circuit board etc.

Further, as shown in FIG. 5(b), the E-type core 1b has a first groove 6b and a second groove 7b on both sides of the central magnetic leg 2b having a longitudinally rectangular cross section. A first side magnetic leg 3b and a second side magnetic leg 4b are arranged, and one end of each of the central magnetic leg 2b, first side magnetic leg 3b, and second side magnetic leg 4b is connected by a yoke portion 5b. It is made up of.

According to the E-type core 1b, the width and thickness of the central magnetic leg 2b, the first side magnetic leg 3b, and the second side magnetic leg 4b are made thinner, so that the width and thickness of the transformer or the like in which the E-type core 1b is incorporated is reduced. However, like the E-type core 1a, the coil bobbin 8b shown by the imaginary line is thin.

When fitted onto the central magnetic leg 2b, the upper and lower portions of the winding of the coil bobbin 8b protrude by 2b width from the upper and lower surfaces of the central magnetic leg 2b, making it impossible to reduce the height of the transformer and the like.

Here, while satisfying the condition that the cross-sectional area of the central magnetic leg is equal to the sum of the cross-sectional areas of the first side magnetic leg and the second side magnetic leg, a structural design is performed that effectively utilizes the dimensions of each part of the E-shaped core. A conventional example in which a transformer or the like in which the E-type core is incorporated will be described with reference to FIG. 6.

In the E-type core 1), a central magnetic leg 12 elongated in the horizontal direction extends from a substantially central portion of the front surface of a yoke portion 15, and
A first side magnetic leg 13 and a second side magnetic leg 14 are disposed with a first groove 16 and a second groove 17 on both sides of the central magnetic leg 12, and the first side magnetic leg 13 and the second side magnetic leg 14 have a first groove 16 and a second groove 17. One end of each of the magnetic legs 14 is connected by the yoke portion 15, and the central magnetic leg 12,
The other end surfaces of the first side magnetic leg 13 and the second side magnetic leg 14 are formed on the same surface.

As shown by the imaginary line in FIG. 6, a coil bobbin 18 wound with enameled wire or the like to form a coil is fitted into the central magnetic leg 12 of the E-type core 1). By combining it with an E-type or 1-type core having the same structure as 1), a transformer or the like is formed.

According to the E-type core 1), the central magnetic leg 12 is elongated in the lateral direction, and the first side magnetic leg 13, the 21st side magnetic leg
)1] By having a space above and below the central magnetic leg 12 compared to the height of the Mi leg 14 and the yoke part 15, the coil bobbin 18 fitted in the central magnetic leg 12 can be Since the legs 13, the second side magnetic legs 14, and the yoke part 15 do not protrude beyond the inner walls, the structure is designed to accommodate miniaturization of the E-shaped core 1).

Next, a manufacturing method for manufacturing the E-shaped core 1a using the dry single-acting press device 25 will be described with reference to FIGS. 7(a) and 7(b).

FIG. 7 (at is a plan view showing a state in which the lower mold 23 is fitted into the formwork 21 of the single-acting press device 25;
In b), the granulated powder 24 made of a magnetic material filled in the E-shaped molding hole 21a of the same mold 21 is inserted into the upper mold 22 and the lower mold 2.
FIG. 3 is a cross-sectional view along line A showing a state in which pressure is applied.

The lower mold 23 is inserted from below into the E-shaped molding hole 21a formed in the mold frame 21, and the granulated powder 24 made of a magnetic material is filled into the E-shaped molding hole 21a, and the upper mold 2 is inserted from above.
2 is inserted and pressurized to mold the E-shaped core 1a.

At this time, the pressure surface of the upper mold 22 and the pressure surface of the lower mold 23 are
In order to uniformly pressurize the granulated powder 24, the central magnetic leg 2a, the first side magnetic leg 3a, and the second side magnetic leg of the E-shaped core 1a are formed on substantially horizontal planes and are therefore molded. 4
The upper and lower surfaces of each of a are formed on the same plane.

According to the above-described single-acting breath device 25, the E-type core 1a
has a uniform density in each part, and since the single-acting type breather 25 operates simply, the single-acting type breather 25
It has the characteristics of being small and simple in structure, fast in molding speed, and suitable for mass production.

Note that when iron powder is used as the magnetic material, a powder magnetic core is formed by pressure molding, and when ferrite powder is used, a binder is added to the ferrite powder and granulated. A ferrite core is formed by pressure molding and further firing.

Next, the E-type core 1) is pressed by the double-acting press device 35.
A manufacturing method for manufacturing the same will be explained with reference to FIGS. 8(a) and (b).

FIG. 8(a) is a plan view showing a state in which the lower die 33 is fitted into the formwork 31 of the double-acting press device 35, and FIG.
), the granulated powder 34 made of a magnetic material filled in the rectangular molding hole 31a of the mold frame 31 is inserted into the upper mold 32 and the lower mold 3.
FIG. 3 is a cross-sectional view taken along line B-B showing a state in which pressure is applied.

A lower mold 33 is fitted from below into a rectangular molding hole 31a formed in the formwork 31, and granulated powder 34 made of a magnetic material is filled into the rectangular molding hole 31a, and an upper mold 32 is fitted from above. Pressure is applied by inserting the E-type core 1.
) is molded.

At this time, the first lower mold pressing surface 33a and the second lower mold pressing surface 33b of the lower mold 33 are opposite to the upper mold pressing surface 32a of the upper mold 32.
is configured to double-act and operate, and the central magnetic leg 12 is molded approximately at the center of the front of the yoke portion I5, and the first side magnetic leg 13 and the second side magnetic leg 14 are molded. It is supposed to be done.

According to the double-acting press device 35 described above, the first
Since the lower mold pressure surface 33a and the second lower mold pressure surface 33b double-act to press the granulated powder 34, it is difficult to mold the granulated powder 34 to have a uniform density. , there is a risk that micro-cracks or the like may occur in the E-shaped core 1) due to the double-acting pressure applied by the first lower mold pressurizing surface 33a, etc., and as the double-acting press device 35 becomes larger, The operation control of the device 35 is complicated, and the molding speed is slow, making it unsuitable for mass production.

For this reason, a method of manufacturing an E-type core as shown in FIGS. 9(al to d) has been proposed.

According to this method, a molded member 48 having a rectangular cross section is manufactured by granulating a magnetic material such as ferrite powder, a binder, etc. as granulated powder, and molding it using a single-action press machine (not shown). (Figure (a))
.

The molded member 48 is fired or pre-fired (main firing is performed at the stage where the E-type core forming process is completed), and then two cutting grooves 47a, 4 are formed along the longitudinal direction of the molded member 48.
7b, for example, by cutting using a lathe or the like (FIG. 7(b)).

Next, the molded member 48 is sequentially cut to a predetermined width (FIG. 4(C)).

Through the above steps, the E-shaped core 41 has grooves on both sides of the central magnetic leg 42, and the first side magnetic leg 43 and the second side magnetic leg 4
4 are arranged and formed, and a yoke portion 45 is formed to connect one end of each of the central magnetic leg 42, the first side magnetic leg 43, and the second side magnetic leg 44.

Furthermore, the upper surface of the central magnetic leg 42 and the upper surface of the yoke part 45 in the E-shaped core 41 are cut as a central magnetic leg cutting part 46a and a yoke part cutting part 46b, respectively, and the cutting groove part 46
is processed.

After that, a coil bobbin (not shown) is attached to the central magnetic leg 42.
A transformer or the like is constructed by being fitted into the.

At this time, the upper part of the coil bobbin fitted to the central magnetic leg 42 has the cutting groove 46 formed therein.
Since the first magnetic leg 43 and the second magnetic leg 44 disposed on both sides of the cutting groove 46 are prevented from protruding from the upper surface, they can be stably mounted on electronic circuit boards, etc., and are small and low profile. It was a blessing to the people.

According to the method for manufacturing the E-type core described above, there is no need to use the double-acting type brace device 35, and the E-type core 41 can be manufactured using a similar device and process.

(Problem to be Solved by the Invention) However, according to the above-mentioned conventional method for manufacturing an E-type core, the E-type core is configured such that the coil bobbin can be accommodated efficiently and the height can be made low. When attempting to form the magnetic material using a pressure press, a double-acting type press device must be used as the pressure press device, which makes it difficult to mold the magnetic material to a uniform density, and when forming the magnetic material with a double-acting press. There is a risk that micro-cracks will occur in the E-type core, and the double-acting press device itself will become larger.
There were problems in that the operation control was complicated and the molding speed was slow, making it unsuitable for mass production.

Further, according to the manufacturing method of manufacturing the E-shaped core by molding a magnetic material, cutting grooves, cutting to a predetermined width, and further cutting a part of the central magnetic leg and yoke part, Although it is no longer necessary to use the double-acting type brace, there has been a problem that the number of manufacturing steps increases compared to the case where a single-acting type brace is used.

Furthermore, in the manufacturing method using the double-acting press device and the manufacturing method requiring molding, grooving, cutting and cutting, E
When constructing a transformer or the like by abutting and combining type cores or I-type and E-type cores, it is usually necessary to perform surface polishing on the abutting surfaces of each type, and in addition to the above steps, this surface polishing step is also necessary. There was a problem that .

The present invention has been made in view of the above circumstances, and is an E-type that has a structural design that effectively utilizes the dimensions of each part through a simple manufacturing process without using large-scale molding equipment that is difficult to control. The present invention provides a method for manufacturing an E-type core.

(Means for Solving the Problem) In order to achieve the above object, the present invention includes a central magnetic leg,
An E-type core having a pair of side magnetic legs arranged opposite to each other so as to sandwich the central magnetic leg, and a yoke portion that connects one end of the central magnetic leg and one end of each of the pair of side magnetic legs to each other. In the manufacturing method, a magnetic material is molded into a mouth-shaped shape having a pair of side pillars and a pair of common pillars that respectively connect both ends of the pair of side pillars, and one mouth-shaped surface of the molded body is formed into a plurality of mouth-shaped surfaces. By performing a cutting process so as to divide the common column into two, the central magnetic leg is formed on the common column, and the side columns are used as the side magnetic legs.Furthermore, the pair of side columns are cut to form an E-shaped core. By manufacturing the above object, the above object is achieved.

Further, the present invention provides a method for forming the magnetic material into a mouth shape, and cutting the molded body so as to form a plurality of convex portions on one mouth surface of the molded body. The above object is achieved by forming magnetic legs, using the pair of side columns as the pair of side magnetic legs, and further cutting the pair of side columns to manufacture an E-shaped core. .

(Function) In the present invention, a magnetic material is molded into a mouth shape having a pair of side columns and a pair of common columns connecting both ends of the pair of side columns, respectively, using a single-acting press or the like, Cutting is performed to divide one mouth surface of the molded body into a plurality of parts, and further, by cutting the pair of side pillars approximately at the center, a central magnetic leg and a central magnetic leg are sandwiched between the two side pillars. A pair of E-shaped cores having a pair of side magnetic legs arranged opposite to each other and a yoke portion that connects one end of the central magnetic leg and one end of each of the pair of side magnetic legs can be manufactured at the same time. can.

Further, in the present invention, the magnetic body is molded into a mouth-shaped shape, cutting is performed to form a plurality of convex portions on one mouth-shaped surface of the molded body, and the pair of side pillars are approximately cut out. By cutting at the center, the central magnetic leg, a pair of side magnetic legs facing each other so as to sandwich the central magnetic leg, one end of the central magnetic leg, and one end of each of the pair of side magnetic legs are separated. A pair of E-shaped cores having mutually connected yoke portions can be manufactured at the same time.

In addition, a pair of E-type cores are manufactured by molding a magnetic material into a mouth shape using a small and simple device such as a single-acting press, and cutting and cutting the mouth shape. Therefore, there is no need to use a large and complicated control device such as a double-acting brace.

Further, in the E-type core manufactured by the above manufacturing process, the width of the central magnetic leg is narrower than the width of the pair of side magnetic legs, so that the coil bobbin is fitted into the central magnetic leg. In this case, the amplitude of one coil of the coil bobbin does not protrude beyond the width of the pair of side magnetic legs.

Furthermore, according to the manufacturing process, when cutting is performed to form a plurality of convex portions on one mouth-shaped surface of the mouth-shaped molded body, the E-shaped cores etc. are brought into contact with each other. Surface polishing can be performed at the same time.

(Example) Embodiments of the present invention will be described in detail based on the drawings.

FIG. 1(a) is a perspective view showing an example of the molding process related to the method for manufacturing an E-type core of the present invention, and FIG. 1(b) is a mouth molded member molded by the molding process related to the same example. FIG. 1(C) is a perspective view showing an example of the cutting process according to the same example, and FIG. 1(d) shows a mouth-shaped core formed by the cutting process according to the example. FIG. 1(e) is a perspective view showing a pair of E-shaped cores formed by the cutting process according to the same example, and FIG. 1(f) is a perspective view showing a pair of E-shaped cores formed by the manufacturing method according to the same example. FIG. 2(a) is a perspective view showing a type core, FIG. 2(a) is a front view showing an E-type core manufactured by the manufacturing method according to the same example, and FIG. 2(b) is a front view showing the E-type core manufactured by the manufacturing method according to the same example. FIG. 3(a) is a sectional view showing an X-x cross section of an E-type core; FIG.
4(a) is a plan view illustrating a state in which E-type cores according to the same embodiment are combined; FIG. b) is a plan view illustrating a state in which E-shaped cores according to the same embodiment are combined.

As shown in FIG. 1(a), approximately in the center of the formwork 51,
A rectangular rectangular hole 51c is formed by molding, etc., and a central column 51b is formed in the center of the rectangular hole 51c.
By arranging the opening hole 51a, the opening hole 51a is formed.
The mouth hole 51a is female-shaped.

From below the mouth mold hole 51a of the formwork 51, the mouth mold hole 51
A lower mold 53 having the same shape as a is used as a male mold, and its upper part is inserted as shown by arrow I in the figure.

The mouth hole 51a is filled with granulated powder 54 made of a magnetic material.

From above the mouth hole 51a filled with the granulated powder 54,
An upper mold 52 having the same shape as the mouth mold hole 51a and the lower mold 53 serves as a male mold, and its lower part is inserted therein as shown by the arrow ■ in the figure.

Therefore, the single-acting breath device 55 configured as described above
The granulated powder 54 filled in the mouth hole 51a of the upper mold 5
2 upper mold pressure surface 52a and lower mold pressure surface 53a of the lower mold 53
The opening molding member 6 shown in FIG. 1(b) is pressurized by
It is molded into 1.

The mouth-shaped molded member 61 has a pair of first side posts 62 and a second side post 63 arranged on both sides, and the first side post 62 and the second side post 63 are arranged on both sides.
Both ends of the side pillars 63 are connected by a pair of first common pillars 64 and second common pillars 65, respectively, and the upper mold pressing surface 52a of the upper mold 52 and the lower mold pressing surface 53a of the lower mold 53 are configured. The first side post 62, second side post 63 . First common pillar 64
The upper and lower surfaces of each of the second common pillars 65 and 65 are formed on the same plane.

Next, as shown in FIG. 1(c), a grinder device 73 in which twin wheels of a first disc type grinder 71 and a second disc type grinder 72 made of an abrasive material etc. are pivotally attached to a rotating shaft 74. is rotationally driven in the direction of the arrow (■) in the figure by a drive device (not shown), and the mouth molding member 61 is moved in the direction of the arrow (-) in the figure by a moving mechanism (not shown).

Therefore, the common pillar 64 of the mouth molding member 61
Along the inner edges of the side columns 62 and the second side columns 63, the grinder device 73 cuts a cutting depth according to the width of the first cutting surface 71a and the second cutting surface 72a and the installation height of the rotating shaft 74 of the grinder device 73. Figure 1(d)
As shown in , a mouth-shaped core 80 is formed.

The mouth-shaped core 80 is formed into the first common column 6 by the cutting process.
A first cutting groove 86 and a second cutting groove 87 are formed on both sides of the common column 4 and the second common column 65.

Next, as shown in FIG. 1(e), in the longitudinal direction of the first common column 64 and the second common column 65 in the mouth-shaped core 80, the first side column 62 and the second side column 63 are The approximately middle arrow part is cut, and the first side post 62 is cut into the front first side post 62. Side pillar 6
2a, a rear first side column 62b, and a second side column 63 are separated into a front first side column 63a and a rear first side column 63b, and a pair of first
An E-type core 81a and a second E-type core 81b are formed.

Here, if we take the aforementioned first E-type core 81a as an example, the first
As shown in Figure (f), the upper part of the first common column 64 becomes the central magnetic leg 82, and the lower part of the first common column 64 becomes the yoke part 85.
Therefore, the front first side pillar 62a and the rear front first side pillar 63a
constitute the first side magnetic leg 83 and the second side magnetic leg 84, respectively.

At this time, in the first E-type core 81a, as shown in FIG. 2(a), the upper mold pressing surface 52a and the lower mold pressing surface 53a of the single-acting type brace device 55 form a flat surface as described above. As a result, the central magnetic leg surface 82a of the central magnetic leg 82 of the E-shaped core 81a, the first side magnetic leg surface 83a of the first side magnetic leg 83, and the second side magnetic leg surface 84a of the second side magnetic leg 84, are arranged on the same plane, and the lower surface of the E-shaped core 81a also forms a plane.

Further, in the E-shaped core 81a, as shown in FIG. 2(b), the area of the central magnetic leg surface 82a is twice the area of the first side magnetic leg surface 83a and the second side magnetic leg surface 84a. At the same time, the height H of the central magnetic leg 82 is higher than that of the first side magnetic leg 83 and the second side magnetic leg 83.
The height is lower than the height H of the side magnetic leg 84.

That is, as shown by imaginary lines in FIG. 1(d) and FIG. 2(b), a coil bobbin 88 made of a coil or the like wound with enameled wire or the like is fitted into the central magnetic leg 82. When this is done, the upper part of the winding of the coil bobbin 88 no longer protrudes from the height H- of the first side magnetic leg 83 and the second side magnetic leg 84.

According to this embodiment, the small and simple single-acting breath device 5
5, the magnetic material is molded into a mouth-shaped molded member 61, and a pair of first side columns 62 and a second side pillar in the mouth-shaped molded member 61 are formed.
The mouth-shaped core 80 is manufactured by cutting the first common pillar 64 and the second common pillar 65 along the inner edge of the side pillar 63, and the mouth-shaped core 80 is then cut into the first common pillar 64 and the second common pillar 65. A pair of first E-type cores 81a and second E-type cores 81b are manufactured by cutting the second common column 65 in the longitudinal direction and approximately at the center of the first side column 62 and second side column 63. This eliminates the need for complicated manufacturing processes.

In addition, a pair of E-shaped cores 8 are formed to efficiently house the coil bobbin and have a low profile so that they can be mounted on an electronic circuit board, etc.
In manufacturing 1a and 81b, there is no need for a large double-acting press device with complicated operation control, so the magnetic material can be press-molded with uniform density, the molding speed is improved, and mass production is possible. This makes it possible to prevent microcracks and the like from occurring in the E-shaped core.

Furthermore, in the pair of E-shaped cores 81a and 81b manufactured by the above manufacturing process, the height H of the central magnetic leg 82 is lower than the height H- of the pair of first side pillars 62 and second side pillars 63. The coil bobbin 88 is formed on the back of the central magnetic leg 8.
2, the amplitude of one coil of the coil bobbin 88 does not protrude beyond the pair of first side pillars 62 and second side pillars 63. A transformer or the like in which the cores 81a and 81b are incorporated can be stably mounted.

Note that the first cutting surface 71a of the first disc type grinder 7e of the grinder device 73 and the second disc type grinder 72
When each ridge of the second cutting surface 72a is curved, the mouth-shaped molded member 61 has the first cutting groove 86 and the second cutting groove 87 cut by the grinder device 73.
By applying a curved surface to the lower portion of each of the E-shaped cores 81a and 81b, it is possible to prevent microcracks from occurring in the E-shaped cores 81a and 81b.

Further, the ridges of the first disc type grinder 71 and the second disc type grinder 72 of the grinder device 73 are not limited to being curved, for example, the first disc type grinder 71 and the second disc type grinder 72 It is also possible to apply taber processing to the surface.

Furthermore, a transformer or the like is constructed by fitting two coil bobbins into the first common column 64 and the second common column 65 of the mouth-shaped ferrite core 80 obtained by cutting the mouth-shaped molded member 61 using the grinder device 73. It's okay.

Next, another embodiment of the present invention will be described with reference to FIG.

In this embodiment, the same parts as in the previous embodiment are given the same reference numerals, and the description thereof will be omitted.

As shown in FIG. 1(a), granulated powder 24 made of a magnetic material is molded into a mouth molding member 61 by a single-acting press 55. As shown in FIG.

As shown in FIG. 3(a), the grinder device 91 includes a central polishing grinder 92 sandwiched between the first disc type grinder 71 and the second disc type grinder 72, and each of the grinders. A first abrasive grinder 93 and a second abrasive grinder 94 disposed on the sides of the abrasive grinder 94 are each pivotally attached to a rotating shaft 74.

At this time, the central polishing grinder 92, the first polishing grinder 93, and the second polishing grinder 94 cut the first disc in accordance with the cutting depth determined by the installation height of the rotating shaft 74 of the grinder device 91. The diameter is smaller than that of the mold grinder 71 and the second disc type grinder 72, and the upper surfaces of the common pillar 64, the first side pillar 62, and the second side pillar 63 are polished. .

By cutting with the grinder device 91, a first cutting groove 86 and a second cutting groove 87 are formed, and the common polished surface 64c of the common column 64 and the first side column polished surface of the first side column 62 are also formed. 62c and the second side post polished surface 63c of the second side post 63 are each surface ground to form the mouth-shaped core 100.

The mouth-shaped core 100 is cut at approximately the center of the first side column 62 and the second side column 63 in the longitudinal direction of the tI41 common column 64 and the second common column 65, thereby forming a pair of A first E-type core 101 and a second E-type core 102 are formed.

At this time, taking the first E-type core 101 as an example, the first common column polished surface 64c of the first common column 64 that has been polished
, the first side post polished surface 62c of the front first side post 62a and the second side post polished surface 63C of the second side post 63 are respectively connected to the central magnetic leg 8.
2, the first magnetic leg polishing surface 83b of the first magnetic leg 83, and the second magnetic leg polishing surface 84b of the second magnetic leg 84.

The first E-type core 101 and the second E-type core 102 are combined, and the coil bobbin 88 is fitted to the central magnetic leg 82, etc., to form a transformer, etc., as shown in FIG. 3(b). .

At this time, the transformer and the like are the central magnetic leg polished surface 82b of the first E-type core 101, the first side magnetic leg polished surface 83b, and the second side M
The i-leg polishing surface 84b and the respective corresponding surfaces of the second E-type core 102 are brought into contact with each other and fixed by fixing fittings (not shown), but the central magnetic leg polishing surface 82b of the first E-type core 101 Since the first side magnetic leg polishing surface 83b, the second side magnetic leg polishing surface 84b, and the corresponding surfaces of the second E-type core 102 are surface polished, the corresponding surfaces can be brought into close contact with each other. , it is possible to perform reliable assembly without degrading the magnetic properties of the transformer, etc.

Furthermore, according to the manufacturing process, when cutting is performed to form a plurality of convex portions on one mouth-shaped surface of the mouth-shaped molded body, the central magnetic legs and the pair of Since surface polishing of the abutting surfaces of the side magnetic legs on which the E-type cores and the like are combined can be performed at the same time, the surface polishing process of the corresponding abutting surfaces, etc. can be omitted.

Next, another embodiment of the present invention will be described with reference to FIG.

In this embodiment as well, similar to the previous embodiment, the same reference numerals are given to the same reference numerals, and the explanation thereof will be omitted.

Mouth molding member 61 molded in FIG. 1(a)
is 1. As shown in FIG. 4(a), the central polishing grinder 92 of the grinder device 91 is cut by a grinder device 96 that is replaced with a central cutting grinder 97 having a larger diameter than the central polishing grinder 92. , mouth-shaped core l 1. l is formed.

At this time, for example, the first
The upper part of the common column 64 is cut to form a central magnetic leg 98 having a lower height than the first common column 64, and the upper surface of the central magnetic leg 98 has a cut surface 98a of the central magnetic leg which is surface-polished at the same time as cutting. It consists of

The mouth-shaped core 1) 1 is located in the elongated direction of the first common column 64 and the second common column 65, and in the longitudinal direction of the first side column 62 and the second common column 65.
A pair of first E-type core 106 and second E-type core 107 are formed by cutting the side post 63 at approximately the center.

At this time, taking the first E-type core 106 as an example, the first common column polished surface 64c of the first common column 64 that has been cut and polished, the first side column polished surface 62c of the front first side column 62a, and The second side polished surface 63c of the second side column 63 is the central magnetic leg cutting surface 98a of the central magnetic leg 98, the first side magnetic leg polished surface 83b of the first side magnetic leg 83, and the second side magnetic leg 84, respectively. The second side magnetic leg polishing surface 84b.

The first E-type core 106 and the second E-type core 107 are combined, and the coil pobbin 88 is fitted to the central magnetic leg 98, etc., to form a transformer, etc., as shown in FIG. 3(b). .

At this time, a central gap 1 exists between the central magnetic leg 98 of the first E-type core 106 and the opposing central magnetic leg of the second E-type core 107.
) 0 is set.

The central gap 1)0 can be formed by arbitrarily providing a gap,
The magnetic characteristics of transformers etc. can be adjusted.

Therefore, according to this embodiment, the central gap 1)0 for magnetic adjustment of a transformer or the like in which an E-shaped core is incorporated can be formed simultaneously with the cutting process, and surface polishing can also be performed.

Note that when iron powder is used as the magnetic material, a powder magnetic core is formed by pressure molding, and when ferrite powder is used, a binder is added to the ferrite powder and granulated, followed by pressure molding. A ferrite core is formed by molding and firing.6Also, in this example, a single-acting press device was used to pressurize the granulated powder.
However, the present invention is not limited to this. (1) For example, a wet extrusion molding machine or the like may be used.

Further, in this embodiment, a rotating disc-shaped grinder device is used for cutting, but the present invention is not limited to this, and for example, a rotating belt-shaped sander or the like may be used.

(Effects of the Invention) Since the method for manufacturing an E-air core according to the present invention is configured as described above, it has the following effects.

(1) Molding the magnetic material into a mouth molding member using a small and simple single-acting press, etc., cutting one mouth-shaped surface of the molded body into multiple parts, and then molding the mouth molding. Since two pairs of E-empty cores can be manufactured by cutting the members, a pair of E-empty cores to be incorporated into a transformer, etc.
This method has excellent effects in that an empty core can be obtained at the same time, and a complicated manufacturing process is not required, making it possible to simplify the manufacturing process.

(2) Also, mold the magnetic material into a mouth molded member, perform cutting to form a plurality of convex portions on one mouth surface of the molded body, and roughly cut the mouth molded member. As a result, it is possible to manufacture a pair of E-empty cores, so it is possible to simultaneously obtain a pair of E-empty cores to be incorporated into a transformer, etc., and it also eliminates the need for a complicated manufacturing process, which simplifies the manufacturing process. It has the excellent effect of being able to

(3) In addition, the E-empty core is formed to efficiently accommodate the fill bobbin and to be low-profile and can be mounted on an electronic circuit board, etc., without having to be molded using a double-acting press device that is large and has complicated operation control. , the magnetic material is molded into a mouth molded member using a single-acting press machine, then processed and cut to produce a pair of E-air cores, so the magnetic material has a uniform density and is press-molded. At the same time, the molding speed is improved,
It has the excellent effect of enabling mass production and further preventing micro-cracks and the like occurring in the E-empty core due to pressurization by a double-acting press device.

(4) Furthermore, in the pair of E-empty cores manufactured by the above manufacturing process, the width of the central magnetic legs is narrower than the width of the pair of side magnetic legs, so that the coil bobbin can be attached to the central magnetic legs. When fitted into the coil bobbin, the amplitude of one of the coils of the coil bobbin does not protrude beyond the width of the pair of side magnetic legs, thus stabilizing the transformer, etc. in which the E-empty core is incorporated in the electronic circuit board, etc. It has the excellent effect of being able to be mounted.

(5) Furthermore, when using E-type cores or a combination of I-type and E-empty cores, it is necessary to perform surface polishing on the abutting surfaces of the cores. According to the method, when performing cutting to form a plurality of convex portions on one mouth-shaped surface of the mouth-shaped molded body, surface polishing of the corresponding contact surface can be performed simultaneously, so that the surface polishing step It has the excellent effect of being able to eliminate the above-described assembly, and also being able to perform the assembly reliably and to prevent deterioration of the magnetic properties.

[Brief explanation of the drawing]

FIG. 1(a) is a perspective view showing an example of the molding process related to the method for manufacturing an E-air core of the present invention, and FIG. 1(b) is a mouth molded member molded by the molding process related to the same example. FIG. 1(c) is a perspective view showing an example of the cutting process according to the same example, and FIG. 1(d) shows a mouth-shaped core formed by the cutting process according to the example. FIG. 1(e) is a perspective view showing a pair of E hollow cores formed by the cutting process according to the same example, and FIG. 1(f) is a perspective view showing a pair of E hollow cores formed by the manufacturing method according to the same example. FIG. 2(a) is a front view showing an E-empty core manufactured by the manufacturing method according to the same example, and FIG. 2(b) is a perspective view showing the empty core. FIG. 3(a) is a perspective view showing an example of the cutting process of another manufacturing method according to the present invention, and FIG. 3(b) is the same example. FIG. 4(a) is a perspective view showing an example of the cutting process of another manufacturing method according to the present invention, and FIG. 4(b) is the same. A plan view illustrating a state in which E-type cores according to the embodiment are combined, FIGS. 5(a) and 5(b) are perspective views showing a conventional E-type core, and FIG. 6 is another conventional E-type core. A perspective view showing the
) is an explanatory diagram explaining the method of manufacturing an E-type core using a conventional single-acting type brace, Figure 7 (b) is a cross-sectional view showing the A-A cross section of the single-acting type brace, and Figure 8 (a) is a conventional method. 8(b) is a cross-sectional view showing the B-B cross section of the double-acting type brace, and FIGS. 9(a) to (b) are It is an explanatory view explaining the manufacturing process of the conventional E type core. 62 ・ 64 ・ 7 l ・ 72 ・ 73 ・ 80 ・ 82 ・ 84 ・ First side column, 63... Second side column, first common column, 65... First disk type grinder, second disk type grinder, grinder device, mouth type core, 81... E type core, central magnetic leg, 83... first side magnetic leg, second side magnetic leg, 85... yoke portion.・Second common pillar,

Claims (2)

[Claims] (1) A central magnetic leg, a pair of side magnetic legs arranged opposite to each other so as to sandwich the central magnetic leg, and a yoke portion that connects one end of the central magnetic leg and one end of each of the pair of side magnetic legs to each other. A method for manufacturing an E-type core having the following steps: molding a magnetic material into a rectangular shape having a pair of side columns and a pair of common columns connecting both ends of the pair of side columns, and forming the molded body. By cutting one square-shaped surface into multiple parts,
The central magnetic leg is formed on the common column, the side columns are used as the side magnetic legs, and the pair of side columns are cut to form E.
A method for manufacturing an E-type core, the method comprising manufacturing an E-type core. (2) By molding a magnetic material into a square shape and cutting it to form a plurality of convex parts on one square surface of the molded body, the central magnetic leg is attached to the pair of common columns. and the pair of side columns are used as the pair of side magnetic legs, and further,
A method for manufacturing an E-type core, which comprises manufacturing an E-type core by cutting the pair of common pillars.