JPH0473916A - Manufacture of e-shaped core - Google Patents

Abstract

PURPOSE:To enable manufacture of E-shaped cores of structure design that each part dimension is effectively utilized by a simple fabrication process with out use of any molding equipment hard to control and troublesome to handle by molding a magnetic material into a H shape for cutting work of one H-shape face into a plurality and by cutting side columns and center common columns. CONSTITUTION:In a manufacture of an E-shaped core 81 having a center mag netic 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 mag netic material is molded into a H 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 common column 64 which couples the center of the side columns 62, 63, and is subjected to cutting work so that one H face of the molded body 61 may be divided into a plurality; thereby, a center mag netic leg 82 is formed in the common columns 64, and the side columns 62, 63 are used as the side magnetic legs 83, 84. Further, the common column 64 is cut to manufacture an E-shaped core 81.

Description

Detailed Description of the Invention (Industrial Application Field) The present 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. The present invention relates to a method for manufacturing an E-type core by performing simple molding and cutting.

(Prior Art) In recent years, there has been an increasing demand for electronic devices to be miniaturized, and in particular, there has been a demand for thin and lightweight electronic devices that can be carried and used outdoors or indoors. There is also a strong desire to reduce the size and weight of transformers, choke coils, noise filters, etc. used in equipment.

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 described with reference to FIGS. 5(a) and 5(b).

In FIG. 5(a), an E-shaped core 1a 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 7, and the central magnetic leg 2a, the first side magnetic leg One end of each of the magnetic 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. They are combined and fixed using fixing fittings (not shown).

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-shaped core 18, when the coil bobbin 8b indicated by the imaginary line is fitted onto the central magnetic leg 2b, the upper and lower windings of the coil bobbin 8b are 25 degrees thinner than the upper and lower surfaces of the central magnetic leg 2b. The width protrudes, making it impossible to make the transformer etc. low in profile.

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 11, a central magnetic leg 12 elongated in the horizontal direction extends from a substantially central portion of the front surface of the 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 are arranged on both sides of the central magnetic leg 12. 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-shaped core 11. By combining it with an E-type or I-type core having the same structure, a transformer or the like is formed.

According to the E-shaped core 11, the central magnetic leg 12 is elongated in the lateral direction, and has a height larger than that of the first side magnetic leg 13, the second side magnetic leg 14, and the yoke part 15. Central magnetic leg 1
By having a space above and below 2, the central magnetic leg 12
The coil bobbin 18 fitted in the 101111iB
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 11.

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(a) 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, and FIG.
), 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 23.
FIG. 3 is a cross-sectional view taken along line AA, 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 a small and simple structure, a fast 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 double-acting brace device 35 causes the E-type core 11 to
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 mold 33 is fitted into the formwork 31 of the double-acting brace 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.
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 15, 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 above double-acting brace device 35, 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 11 due to the double-acting pressure applied by the first lower mold pressurizing surface 33a, etc., and as the double-acting type press device 35 increases in size, The operation control of the device 35 was complicated, and the molding speed was slow, making it unsuitable for mass production.

For this reason, a method of manufacturing an E-type core as shown in FIGS. 9(a) to 9(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-shaped 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. contributed to the

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, which is configured so that the coil bobbin can be efficiently housed and can be made low in profile, cannot be processed. If forming by pressure pressing requires the use of a double-acting press device, it is difficult to mold the magnetic material to a uniform density, and E There is a risk that micro-cracks will occur in the mold 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 press device, there is a problem in that the number of manufacturing steps is increased compared to the case where a single-acting type press device 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, etc. by abutting and combining mold cores or ■-type and E-type cores, it is usually necessary to surface-polish the abutting surfaces of each mold, and in addition to the above-mentioned process, 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-shaped 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 an H-shape having a pair of side pillars and a common pillar connecting the central portions of the pair of side pillars, and one H-shaped surface of the molded body is formed into a plurality of H-shaped surfaces. By performing a cutting process to divide the common column, the central magnetic leg is formed on the common column, and the pair of side columns are used as the pair of side magnetic legs, and the common column is cut to form an E-type. The above objective is achieved by manufacturing the core.

Further, in the present invention, the magnetic material is molded into an H-shape, and cutting is performed to form a plurality of convex portions on one H-shaped surface of the molded body. The above object is achieved by forming legs, using the pair of side columns as the pair of side magnetic legs, and cutting the common column to manufacture an H-shaped core.

(Function) In the present invention, a magnetic material is molded into an H-shape having a pair of side columns and a common column connecting the center portions of the pair of side columns using a single-acting press or the like, and the molded body is By cutting one H-shaped surface into multiple parts, and further cutting the common column along the longitudinal direction, the central magnetic leg and the central magnetic leg are placed opposite each other so as to sandwich the central magnetic leg. A pair of H-shaped cores having a pair of arranged side magnetic legs 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 can be manufactured at the same time.

Further, in the present invention, the magnetic material is molded into an H-shape, cutting is performed to form a plurality of convex portions on one H-shaped surface of the molded body, and the common pillar is further shaped in the longitudinal direction. By cutting along the core, a central magnetic leg, a pair of side magnetic legs arranged opposite to 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 obtained. a yoke portion that connects the E-type ferrite core to each other;
A pair can be manufactured at the same time.

In addition, a pair of H-shaped cores is manufactured by molding magnetic material into an H-shape using a small and simple device such as a single-acting press, and cutting the H-shape. There is no need to use a large and complicated control device such as a dynamic press.

Further, in the H-shaped 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 H-shaped surface of the H-shaped molded body, the E-shaped cores are combined with each other. Surface polishing of the contact surface 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 according to the method for manufacturing an H-shaped core of the present invention, and FIG. 1(b) is an H-shaped molded member formed by the molding process according 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 an H-shaped core formed by the cutting process according to the same example. FIG. 1(e) is a perspective view showing a pair of H-shaped cores formed by the cutting process according to the same example, and FIG. 1(f) is a perspective view showing a pair of H-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 H-type core manufactured by the manufacturing method according to the same example, and FIG. 2(b) is a front view showing the H-type core manufactured by the manufacturing method according to the same example. FIG. 3(a) is a cross-sectional view showing an xx section of an H-shaped 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,
An H-shaped hole 51a is formed through the hole 51a by molding with a metal mold or the like, and the H-shaped hole 51a has a female shape.

From below the H-shaped hole 51a of the formwork 51, the H-shaped hole 51a
The lower mold 53 having the same shape as the male mold is indicated by the arrow 1 in the figure.
The upper part is inserted as shown in .

The H-shaped holes 51a are filled with granulated powder 54 made of a magnetic material.

From above the H-shaped hole 51a filled with the granulated powder 54,
An upper mold 52 having the same shape as the H-shaped hole 51a and the lower mold 53 is used as a male mold, and its lower part is inserted 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 H-shaped holes 51a of the upper mold 5
2 upper mold pressure surface 52a and lower mold pressure surface 53a of the lower mold 53
The H-shaped molded member 6 shown in FIG. 1(b) is pressurized by
It is molded into 1.

The H-shaped molded member 6e has a first side pillar 62 having a first front side pillar 62a and a first rear side pillar 63b on both sides, and a second side pillar 62 having a first front side pillar 63a and a first rear side pillar 63b. A side post 63 is disposed, and a common post 64 connects the first side post 62 and the second side post 63 at approximately the center, and the upper mold pressing surface 52a of the upper mold 52 and the lower mold 53 Since the lower die pressure surface 53a of the H
The upper and lower surfaces of each of the first side column 62, second side column 63, and common column 64 of the molding member 61 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 H-shaped molding member 61 is moved in the direction of the arrow (■) in the figure by a moving mechanism (not shown).

Therefore, the common column 64 of the H-shaped molded member 61 is
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, an H-shaped core 80 is formed.

The H-shaped core 80 has a first cutting groove 86 and a second cutting groove 87 formed on both sides of the common column 64 by the cutting process.

Next, as shown in FIG. 1(e), the H-shaped core 80 is cut along the approximate longitudinal center of the common column 64, so that the common column 64 is common pillar 6
4a and the second common pillar 64b, and a pair of first E
A type core 81a and a second E-type core 81b are formed.

At this time, since the H-shaped core 80 is formed line-symmetrically with respect to the center in the longitudinal direction of the common column 64, the first E-shaped core 81a and the second E-shaped core 81b have the same shape. .

Here, taking the first E-type core 81a as an example, as shown in FIG. 1(f), the upper part of the first common pillar 64a becomes the central magnetic leg 82, and the lower part of the first common pillar 64a becomes Yoke part 8
5, the front first side pillar 62a and the rear 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 Hl of the central magnetic leg 82 is lower than the height H2 of the first side magnetic leg 83 and the second side magnetic leg 84.

That is, as shown by imaginary lines in FIG. 1(d) and FIG. 2(b), a coil pobbin 88 composed 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 an H-shaped molded member 61, and one H-shaped surface of the H-shaped molded member 61 is divided into a plurality of inner edges of the first side pillar 62 and the second side pillar 63. By cutting the common pillar 64 along the H-shaped core 80
By manufacturing the H-shaped core 80 and cutting the common column 64 approximately along the center in the longitudinal direction, a pair of the first E-shaped core 81a and the second E-shaped core 81b can be manufactured. Manufacturing process becomes unnecessary.

In addition, a pair of Japanese-type cores 8 are formed to efficiently house the coil bobbin and have a low profile so that they can be mounted on electronic circuit boards, etc.
In manufacturing 1a and 81b, there is no need for a large double-acting press device with complicated operation control, so the granulated powder can be pressure-molded with uniform density, the molding speed is improved, and large quantities can be produced. Production becomes possible, and furthermore, microcracks and the like occurring in the day-type core can be prevented.

Furthermore, in the pair of Japanese-type cores 81a and 81b manufactured by the above manufacturing process, the height H of the central magnetic leg 82 is greater than the height H of the pair of first side pillars 62 and second side pillars 63. By being formed with a low profile, when the coil bobbin 88 is fitted into the central magnetic leg 82, the amplitude of one coil of the coil bobbin 88 is lower than that of the pair of first side columns 62 and second side columns 63. There is no protrusion, so a transformer or the like in which the Japanese type cores 81a and 81b are incorporated can be stably mounted on an electronic circuit board or the like.

Note that the first cutting surface 71a of the first disc type grinder 71 and the second disc type grinder 72 of the grinder device 73
The ridges of the second cutting surfaces 72a are curved (and the H-shaped molded member 61 has a first cutting groove 86 and a second cutting groove 87 cut by the grinder device 73).
By applying a curved surface to the lower portion of each of the E-type ferrite cores 81a and 81b, it is possible to prevent microcracks from occurring in the E-type ferrite 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 using a Japanese-type core 80 obtained by cutting the Japanese-type molded member 61 using a grinder device 73, and fitting a coil bobbin into the common column 64 of the Japanese-type core 80. Good too.

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 an H-shaped molded 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 further, the common column polished surface 64C1 of the common column 64, the first side column polished surface 62c of the first side column 62 The second side pillar polished surfaces 63c of the second side pillars 63 are each surface polished to form the sun-shaped core 100.

The Japanese-type core 100 is cut along the longitudinal center of the common column 64 to form a pair of first E-type cores 1.
01 and a second E-type core 102 are formed.

At this time, taking the first E-type core 101 as an example, the common column polished surface 64c of the polished common column 64, the front first
The first side polishing surface 62c of the side column 62a and the second side polishing surface 63c of the second side column 63 are the central magnetic leg polishing surface 82b of the central magnetic leg 82 and the first side of the first side magnetic leg 83, respectively. The magnetic leg polishing surface 83b and the second side magnetic leg polishing surface 84b of the second side magnetic leg 84 are formed.

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 etc. correspond to the central magnetic leg polishing surface 82b, the first side magnetic leg polishing surface 83b, and the second side magnetic leg polishing surface 84b of the first E-type core 101, and the second E-type core 102. The central magnetic leg polishing surface 82b, the first side magnetic leg polishing surface 83b, and the second side magnetic leg polishing surface of the first E-type core 101 are brought into contact with each other and fixed by fixing fittings (not shown). Since the corresponding surfaces of 84b and the second E-type core 102 are surface-polished, the corresponding surfaces can be brought into close contact with each other, thereby ensuring reliable assembly without degrading the magnetic properties of the transformer, etc. It can be performed.

Furthermore, according to the manufacturing process, one H of the H-shape
When cutting to form a plurality of convex portions on the mold surface, the contact surfaces of the central magnetic leg and the pair of side magnetic legs formed by the cutting process, where the E-shaped cores are combined, are Since surface polishing can be performed at the same time, the surface polishing process of the corresponding contact surface can be omitted.

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

Similarly, in this embodiment, the same parts as in the previous embodiment are denoted by the same reference numerals, and the explanation thereof will be omitted.

H-shaped molded member 61 molded in FIG. 1(a)
As shown in FIG. 4(a), the grinder device 9
One central polishing grinder 92 is cut by a grinder device 96 that is replaced by a central cutting grinder 97 having a larger diameter than the central polishing grinder 92, thereby forming an H-shaped core 111.

At this time, the common column 64 is cut by the central cutting grinder 97.
The upper part of the central magnetic leg 98 is cut to form a central magnetic leg 98 having a lower height than the common column 64, and the upper surface of the central magnetic leg 98 is a cut surface 98a of the central magnetic leg, which is surface-polished at the same time as cutting.

The H-shaped core 111 is cut along the longitudinal center of the common column 64 to form a pair of first E-shaped cores 1.
06 and a second E-type core 107 are formed.

At this time, if the first E-type core 106 is taken as an example, the common column polished surface 64 of the common column 64 that has been cut and polished is
c, the first side column research surface 62c and the second front side column 62a
The second side post polishing surface 63c of the side post 63 is the center magnetic leg cutting surface 98a of the center magnetic leg 98, the first side magnetic leg grinding surface 83b of the first III magnetic leg 83, and the second side magnetic leg cutting surface 83b of the second side magnetic leg 84, respectively. The side magnetic leg has a polished 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.
10 are provided.

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

Therefore, according to this embodiment, the central air 11Jtll performs magnetic adjustment of a transformer or the like in which an E-type 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. A ferrite core is formed by pressure molding and further firing.

In addition, in this example, in order to pressurize the granulated powder,
Although a single-acting press machine is used, the present invention is not limited to this, and 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-type core according to the present invention is configured as described above, it achieves the following effects.

(1) Molding a magnetic material into an H-shaped member using a small and simple single-acting press, etc., and
A pair of H-shaped cores can be manufactured by cutting the mold surface into multiple parts and then cutting the H-shaped molded member. It has the excellent effect that it can be obtained at the same time, and that a complicated manufacturing process is unnecessary and that the manufacturing process can be simplified.

(2) Also, molding the magnetic material into an H-shaped molded member,
A pair of H-shaped cores can be manufactured by performing cutting to form a plurality of convex portions on one H-shaped surface of the H-shaped molded member and further cutting the H-shaped molded member. This method has excellent effects in that a pair of H-shaped cores to be incorporated into a transformer or the like can be obtained at the same time, and a complicated manufacturing process is not required, thereby simplifying the manufacturing process.

(3) In addition, the H-shaped core, which accommodates the coil bobbin efficiently and is formed to have a low profile so that it can be mounted on electronic circuit boards, etc., is not molded using a large double-acting press machine with complicated operation control. , the magnetic material is molded into an H-shaped molded member using a single-acting press machine, processed and cut to produce a pair of H-shaped cores, so the granulated powder has a uniform density and is pressurized. Along with being molded, the molding speed is improved,
It has the excellent effect of enabling mass production and preventing microcracks and the like occurring in the H-shaped core due to pressurization by a double-acting press device.

(4) In addition, in the H-shaped 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. When installed, the amplitude of one coil of the coil bobbin does not protrude beyond the width of the pair of side magnetic legs, so that the transformer etc. in which the H-shaped core is incorporated in an electronic circuit board etc. can be stably mounted. It has the excellent effect of being able to be mounted.

(5) Furthermore, when using E-type cores or I-type and H-type cores in combination, it is necessary to perform surface polishing on the abutment surfaces of the cores, but the above manufacturing process According to the method, when performing cutting to form a plurality of convex portions on one H-shaped surface of the H-shaped molded body, surface polishing of the corresponding contact surface can be performed simultaneously, so that the surface polishing can be performed simultaneously. This method has excellent effects in that it is possible to eliminate a number of steps, the assembly can be performed reliably, and deterioration of magnetic properties can be prevented.

[Brief explanation of drawings]

FIG. 1(a) is a perspective view showing an example of the molding process according to the method for manufacturing an H-shaped core of the present invention. FIG. 1(b) is an H-shaped molded member formed by the molding process according 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 an H-shaped core formed by the cutting process according to the example. FIG. 1(e) is a perspective view showing a pair of H-shaped cores formed by the cutting process according to the same example, and FIG. 1(f) is a perspective view showing a pair of H-shaped cores formed by the manufacturing method according to the same example. FIG. 2(a) is a front view showing an H-shaped core manufactured by the manufacturing method according to the same example, and FIG. 2(b) is a perspective view showing the H-type core manufactured by the manufacturing method according to the same example. FIG. 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 a plane view showing a state in which E-shaped cores according to the same example are combined. FIG. 4(a) is a perspective view showing an example of the cutting process of another manufacturing method according to the present invention. FIG. 4(b) is a plan view illustrating a state in which E-type cores according to the same embodiment are combined; FIGS. 5(a) and (b) are perspective views showing a conventional H-type core; FIG. is a perspective view showing another conventional H-shaped core, FIG.
) 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 H type core. 81 ・H-type core,

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. In a method for manufacturing an E-shaped core, a magnetic material is molded into an H-shape having a pair of side pillars and a common pillar connecting the central parts of the pair of side pillars, and one of the molded bodies is By cutting the H-shaped surface into a plurality of parts, the central magnetic leg is formed on the common column, the pair of side columns are used as the pair of side magnetic legs, and the common column is formed into the pair of side magnetic legs. A method for manufacturing an E-type core, which comprises cutting the E-type core. (2) Molding the magnetic material into an H shape, and
By performing a cutting process to form a plurality of convex portions on the shaped surface, the central magnetic leg is formed on the common column, and
E characterized in that the pair of side columns are used as the pair of side magnetic legs, and the common column is further cut to produce an E-shaped core.
Method of manufacturing mold core.