JPH05267080A - Choke coil - Google Patents

Abstract

PURPOSE:To facilitate a winding operation of a winding and to improve productivity by axially and radially fixing a pair of core halves to be coaxially connected. CONSTITUTION:A flat type conductor 1 is laterally bent and wound on a core part 2a, the conductor 1 is superposed in a thickness direction in an axial direction of the part 2a thereby to form a single layer winding. Windings of the single layer winding are aligned in the same direction, coaxially arranged, and connected through a central insulation bobbin 80 between a left side winding terminal connector 1b and a right side winding terminal connector 1b opposed to each other. A first holder 74 is mounted on a pair of core halves 2 by a predetermined spring force over both axial ends from behind the halves 2 while a second holder 70 is mounted by a predetermined spring force over both radial ends from behind the halves 2. Thus, a winding operation of the winding on a coil is facilitated, and productivity can be improved.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a choke coil.

[0002]

2. Description of the Related Art Conventionally, a toroidal core has been known as a ferrite core used for a choke coil, and a winding is wound around this toroidal core.

[0003]

In such a toroidal core, since the core has an endless ring shape, it takes much time to manually wind the winding, which lowers productivity and increases labor costs. was there. The present invention has been made in view of the above-described conventional problems, and by fixing a pair of core halves that are coaxially connected to each other in the axial direction and the radial direction, the winding work of the winding is facilitated, and the production is performed. It is an object of the present invention to provide a choke coil capable of improving its performance.

[0004]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, according to the present invention, a rectangular conductor is bent in the width direction and wound around a core part magnetically coupled to a yoke part, and in the axial direction of the core part. A pair of core halves, each of which has a single-layer winding formed by stacking rectangular conductors in the thickness direction, are coaxially connected to both sides of the central insulating bobbin so as to straddle both ends of the core halves in the axial direction. Accordingly, the first holder that presses both core halves inward in the axial direction with a predetermined spring force is attached, and the core halves straddle both ends of the core half in the radial direction. A second holder for pressing both core halves inward in the radial direction with a predetermined spring force is mounted.

[0005]

According to the present invention, a pair of core halves each having a single-layer winding made of a plurality of rectangular conductors wound around the core are connected coaxially on both sides of the central insulating bobbin. As compared with the conventional toroidal core, it becomes easier to wind the winding around the core, and the working efficiency is improved.

[0006]

Embodiments of the present invention will be described below with reference to the accompanying drawings. In the present embodiment, an example in which the choke coil according to the present invention is used in an outlet with a noise filter will be shown.
FIG. 2A shows the internal circuit of the outlet.
Each of the terminal portion T connected to the commercial power source and the blade receiving portion R connected to the plug has a grounding pole in addition to two poles for power feeding. An earth terminal E is connected to the ground electrode of the blade receiving portion R. A noise filter NF is inserted between the terminal portion T and the blade receiving portion R.

Among the components constituting the noise filter NF, the surge absorbing element Z and the capacitors C _{1 to} C ₄ are
The printed circuit board 41 is mounted on the circuit board 41 (see FIG. 8).
reference). Further, the jumper wire J is used as needed. The choke coil CH is shown in FIGS. 1 and 2 (b) (c).
As shown in FIG. 5, a flat rectangular conductor 1 having a flat rectangular cross section with a large aspect ratio is wound around a pair of core halves 2 as a winding. This choke coil CH basically comprises a pair of core halves 2
, A central insulating bobbin 80, a first holder 74, and a second holder 70. As shown in FIG. 3, the pair of core halves 2 includes a cylindrical core portion 2a and a yoke portion 2b that faces a part of the peripheral surface of the core portion 2a.
One end of the core portion 2a and one end of the yoke portion 2b are integrally connected via the side plate portion 2c, and are formed as a continuous body of a magnetic material such as ferrite. A single-layer winding is formed by bending the flat conductor 1 in the width direction and winding the flat conductor 1 around the core 2a, and stacking the flat conductor 1 in the thickness direction in the axial direction of the core 2a. It As shown in FIGS. 2 and 3, the single-layer winding is arranged on the same axis with the winding directions of the windings aligned in the same direction and is coaxially arranged, and the left winding terminal connecting portion is abutted against each other. A central insulating bobbin 80 is inserted between the winding terminal connecting portion 1a on the right side and the winding terminal connecting portion 1a on the right side.

The central insulating bobbin 80 has a cylindrical core portion 81 fitted onto the core portion 2a of the core half 2 and a core portion 8 thereof.
The upper and lower insulating parts 82 and 83 are connected to the first insulating part 82, and the annular brim part 84 is formed on the outer circumference of both insulating parts 82 and 83. The upper insulating portion 82 contacts the left winding terminal connecting portion 1b and the right winding end surface 1a ′, respectively,
Further, the lower insulating portion 83 is in contact with the left winding end surface 1b 'and the right winding terminal connecting portion 1a, respectively.
The left winding terminal connecting portion 1b is pulled out to the front side from the upper cutout portion 85 formed in the annular collar portion 84, and the right winding terminal connecting portion 1a is pulled out to the front side from the lower cutout portion 86. It is like this.

As described above, the end faces of the single-layer windings 1 having the same shape are connected to each other via the central insulating bobbin 80 which is a synthetic resin molded product, and the core is formed by the second holder 70 and the first holder 74. By holding the halves 2 and 2, it is possible to form a compact choke coil CH having a pair of windings with a turn ratio of 1: 1. Each winding of the choke coil CH is wound so that an inductance is hardly generated for a normal mode voltage and a large inductance is generated for a common mode voltage. Further, the end portion of each flat conductor 1 is electrically connected to a conductive member forming the terminal portion T and the blade receiving portion R, respectively.

The pair of core halves 2 are provided with a first holder 74 extending from the rear side thereof to both axial end portions thereof.
Is installed. The first holder 74 is made of an elastic metal material such as a stainless spring, and has a substantially U-shaped plane, as shown in FIGS.
As shown in (c), a pair of left and right pressing pieces 75, 76.
Pinch the core halves 2 and 2 from the left and right sides with a predetermined spring force, and the tips 75a and 76a thereof are locked by the ribs 98 on the body side from the left and right sides. Also, the first holder 7
The upper and lower pressing pieces 77 of 4 are locked to the upper and lower ends of the core halves 2 and 2.

On the other hand, the second holder 70 is made of the same material as that of the holder 74, and is mounted from the rear side of the core halves 2 and 2 over both radial ends thereof. This second
The holder 70 includes a pair of left and right connecting pieces 73 and a pair of upper and lower pressing pieces 71, 72 connected to both ends of the connecting piece 73.
As shown in FIGS. 5A and 5B, the plate-shaped portions of the pressing pieces 71 and 72 clamp the core halves 2 and 2 from the left and right sides with a predetermined spring force, and (A) (b)
As shown in FIG. 5, the T-shaped portions of the pressing pieces 71 and 72 are supported from both sides by the body side supporting portions 99, whereby the holder 70 is positioned in the front-rear and left-right directions with respect to the core halves 2 and 2. Has been done.

According to the above structure, a pair of core halves 2 and 2 formed by winding a single-layer winding composed of a plurality of rectangular conductors 1 around the core portion 2a are coaxially provided on both sides of the central insulating bobbin 80. Since the connection is made, winding of the winding wire on the core becomes easier as compared with the conventional toroidal core,
Work efficiency increases. Further, by winding the rectangular conductor 1 forming the single-layer winding densely, the winding itself can be made dense in the axial direction. Moreover, the gap between the winding and the yoke portion 2b is smaller than that of the winding in the conventional toroidal core, so that the entire coil block can be made compact. Further, the first and second holders 74 and 70 are mounted so as to straddle both ends of the pair of core halves 2 and 2 in the axial direction and the radial direction, so that the core halves 2 and 2 are axially attached to each other. Since the cores are pressed against each other inward in the radial direction and inward in the radial direction, the cores are strongly pressed against each other, the mutual displacement between the two cores can be prevented, and the magnetic resistance can be reduced to reduce the inductance. It is possible to increase. In addition, since the core halves 2 and 2 are pressed by the holders 70 and 74 from above and below and to the left and right by the spring force, vibrations from the outside can be prevented.
It can be absorbed at 0 and 74, and the adverse effect on the choke coil due to vibration can be prevented.

Further, in the present embodiment, the choke coil CH shown in FIG. 1 is connected to both side surfaces of the central insulating bobbin 80 by connecting the terminal connection portion 1a of one single-layer winding and the terminal connection of the other single-layer winding. Since the parts 1b are brought into contact with each other, both terminal connection parts 1a,
Since 1b is arranged in a plane substantially perpendicular to the axis, there is no useless space in the axial direction between the central insulating bobbin 80 and each winding. That is, since the dimension in the width direction of the core is reduced by about one flat conductor (for example, about 1 mm) of the single-layer winding, the yoke portion 2c is reduced.
It is possible to give the core a dimensional allowance, for example, by making the wall thicker. As a result, the cross-sectional area of the loop made by the core can be increased, and the effective length of the core is shortened (about 2 mm).
As a result, the inductance is increased and the coil performance can be improved. In addition, since the same shape of single-layer winding can be shared, expensive winding jigs need only be used for one direction, and the time spent for parts management can be halved compared to the conventional method, greatly improving productivity. And the cost can be reduced.

The internal circuit configured as described above is housed in a case 10 made of synthetic resin which is an insulating material. Case 1
As shown in FIG. 7, 0 is for 3 large squares that are standardized for wiring equipment that is mounted in the mounting surface using an embedded box in the JIS standard or the Japan Wiring Equipment Manufacturers Association standard. It is formed to have the size of three unit wiring accessories that can be mounted on the mounting frame of up to three. That is, it is formed in such a size that only one can be attached to the standardized attachment frame. The case 10 is formed by connecting a body 11 having a front surface (upper surface in FIG. 7) opened and a cover 12 connected to the front surface of the body 11 using a pair of metal assembly frames 13. The assembly frame 13 is arranged so as to straddle the flanges 14 projecting on both sides of the cover 12, and the leg pieces 13a projecting on both ends and the intermediate part respectively.
Fits into the assembling grooves 11a and 12a formed on the peripheral surfaces of the body 11 and the cover 12. Further, by widening the forked portion 13b formed at the tip of the leg piece 13a, the leg piece 13a is prevented from coming off from the assembly grooves 11a and 12a. In this way, the body 11 and the cover 12 are joined by the assembly frame 13.

Each assembly frame 13 has a pair of coupling pieces 1 facing the side surface of the cover 12 and having a coupling hole 15a.
5 are respectively formed, and a pair of coupling claws 16 are respectively provided on the side edges so as to project. Coupling hole 15a and coupling claw 16
Is coupled to the standardized mounting frame described above,
The coupling hole 15a is sized to correspond to a metal mounting frame, and the coupling claw 16 is dimensioned to correspond to a synthetic resin mounting frame.

The inside of the body 11 is divided into a first storage chamber 17a and a second storage chamber 17b. First storage room 17
The letter a stores the terminal portion T and the blade receiving portion R, and is further divided into small sections so that the conductive members do not come into contact with each other. The noise filter NF is stored in the second storage chamber 17b. On the other hand, the cover 12 has three blade insertion holes 18a, 18b, corresponding to the first storage chamber 17a.
18c is opened, and a terminal 19 serving as an earth terminal E is attached to the second storage chamber 17b. Terminal 19
Comprises a substantially U-shaped base plate 19a having a pair of fixing leg pieces 19c inserted into the cover 12, and a terminal screw 19b screwed into the center of the base plate 19a. The fixing leg piece 19c is
The cover 12 is formed by penetrating to the inner surface side of the cover 12 through a through hole 12b formed in the front surface of the cover 12 and expanding the forked portion 19d provided at the tip of the fixing leg piece 19c.
Fixed to. Further, inside the cover 12, a blade-shaped lead plate 19e is electrically connected to the fixing leg piece 19c, and when the cover 12 is coupled to the body 11, the lead plate 19e will be a ground electrode terminal plate described later. It is designed to be electrically connected to 27.

In the first storage chamber 17a of the body 11, as shown in FIG. 7, a pair of terminal plates 21 and 22 connected to the power supply line in the terminal portion T and a power supply line in the blade receiving portion R are connected. Lead plates 25 and 26 having a pair of blade receiving springs 23 and 24 connected to each other, and a blade receiving spring 2 connected to a ground wire.
8 holding ground electrode terminal plate 27 and choke coil CH
A heat radiating plate 29 for radiating heat is stored.

Each of the terminal plates 21 and 22 includes two pairs of terminal pieces 21a and 22a facing each other, and the lock springs 21b and 2 are provided between the terminal pieces 21a and 22a of each pair.
2b is provided. The lock springs 21b and 22b are formed by bending both ends of a strip-shaped plate spring, and forming a locking piece and a contact piece, each end of which is opposed to the terminal pieces 21a and 22a. The electric wire inserted between the locking piece and the contact piece and the terminal pieces 21a and 22a is clamped between the terminal pieces 21a and 22a by the spring force of the locking springs 21b and 22b. Further, the locking piece is slanted so as to reduce the distance from the terminal pieces 21a and 22a in the inserting direction of the electric wire, engages with the electric wire, and holds the electric wire. Each terminal board 21,2
Between the pair of lock springs 21b and 22b provided for the two, release buttons 21c and 22c are provided so as to abut the locking piece. With the electric wire being sandwiched between the terminal pieces 21a and 22a and the lock springs 21b and 22b, the locking piece is moved to the terminal piece 21.
release button 21c, 22
When acting on c, the engagement state of the locking piece with the electric wire is released, and the electric wire can be pulled out. As shown in FIGS. 11 and 12, on the rear surface of the body 11,
Electric wire insertion holes 31 and 32 for introducing an external electric wire for connecting a power supply line of a commercial power source into the case 10, a release button 21c,
Button operation holes 33 and 34 for exposing a part of 22c are formed. Such a structure is a known structure as a quick-connect terminal. Connection pieces 21 are provided on the terminal boards 21 and 22, respectively.
d and 22d are provided, and one terminal plate 21 is the lead wire 2
It is connected to the choke coil CH via 0a. Here, as the lead wire 20a, a relatively long multi-core wire having a relatively large cross-sectional area of about 2 mm ² and forming one loop with the choke coil CH is used. Lead wire 20
The connecting portion between a and the choke coil CH is connected to the circuit board 41 via the lead wire 20b made of wire. Also,
The terminal plate 22 is connected to one connection piece 29b provided on the heat dissipation plate 29, and the other connection piece 29c of the heat dissipation plate 29 is connected to the choke coil CH via the lead wire 20c. The heat dissipation plate 29 is formed of a metal plate having excellent thermal conductivity, and is bent in a meandering shape. A relatively thick multi-core wire having a cross-sectional area of about 2 mm ² is used for the lead wire 20c. Therefore, the heat generated by the choke coil CH is applied to the lead wire 2
Heat is sufficiently dissipated by the heat sinks 0a and 20c and the heat sink 29, and is hardly transmitted to the terminal plates 21 and 22. A cutout 29 serving as a connecting portion is provided in the middle of the heat sink 29.
The heat dissipation plate 29 is connected to the circuit board 41 through the lead wire 20d, which is a wire whose one end is connected to the notch 29a.

On the other hand, the ground electrode terminal plate 27 has two pairs of terminal pieces 27a facing each other (see FIG. 15), and lock springs 27b are arranged between the terminal pieces 27a of each pair. A release button 27c is arranged between the lock springs 27b. That is, a quick-connect terminal is formed similarly to the terminal boards 21 and 22. An electric wire insertion hole 3 for introducing an external electric wire for connecting a ground wire into the case 10 is provided on the rear surface of the body 11.
5 and a button operation hole 36 for exposing a part of the release button 27c are formed (see FIG. 11). By the way, a blade receiving spring 27e is continuously formed on the ground electrode terminal plate 27 via a connecting portion 27d. The blade receiving spring 27e is provided so that the lead plate 19e described above can be sandwiched between a pair of leaf springs facing each other. Therefore, the cover 1 is attached to the body 11.
In the state in which the two are connected, the lead plate 19e causes the blade receiving spring 2
By being held by 7e, the terminal 19 is electrically connected to the ground electrode terminal plate 27. Further, a blade receiving spring 28 for holding the ground blade of the plug is fixed to the ground electrode terminal plate 27. The blade receiving spring 28 is formed in a substantially U shape, and has an arc-shaped cross section parallel to the rear surface of the body 11 to hold the grounding blade between both leg pieces.
The middle portion of the blade receiving spring 28 is fixed to the ground electrode terminal plate 27 using a rivet. Furthermore, the ground electrode terminal plate 27
Is connected to the circuit board 41 through the lead wire 20e made of wire.
Connected to.

The blade receiving springs 23 and 24 for holding the power feeding blades of the plug are each formed in a substantially U shape and hold the power feeding blades between the two leg pieces. 13 and FIG.
As shown in FIG. 3, one leg has an arcuate cross section parallel to the rear surface of the body 11, and the other leg has projections 23a, 24a projecting toward the one leg. With respect to the blade receiving springs 23 and 24, the locking projection 23
After inserting the blade for power supply at a portion where a and 24a are not provided and then rotating the blade along the blade receiving springs 23 and 24, holes formed in the blade for power supply (for blades of general plugs The formed hole) engages with the locking projections 23a and 24a to prevent the plug from coming off.
Intermediate portions of the blade receiving springs 23 and 24 are fixed to the lead plates 25 and 26 using rivets. Each lead plate 25, 26
Cutouts 25a and 26a that serve as connection portions are formed in the circuit board 41, and the lead plates 25 and 26 are connected to the circuit board 41 via the lead wires 20f and 20g that are wires whose one ends are connected to the cutouts 25a and 26a. Further, the lead plates 25 and 26 are provided with connecting pieces 25b and 26b, respectively.
b is connected to the choke coil CH.

The second storage chamber 17a of the body 11 accommodates the choke coil CH and the circuit board 41 on which other components constituting the noise filter NF are mounted. An insulating sheet 42 is interposed between the choke coil CH and the circuit board 41. The electrical connecting portions described above are fixed by using solder. Cover 1
Three blade insertion holes 18a, 18b, 18 formed in 2
As shown in FIG. 9, c is formed in an arc shape in a plane parallel to the front surface of the cover 12, and as shown in FIG. 10, is formed so as to penetrate the front surface of the cover 12. Further, each blade insertion opening 18a, 18b, 18c is formed on an arc having a common center. Each blade insertion port 18a, 18b,
The above-mentioned blade receiving springs 23, 24, 28 are arranged at the portions corresponding to 18c, respectively. If the plugs are inserted into the blade insertion holes 18a, 18b, 18c and then rotated, the power feeding plugs The locking projections 23a and 24a are engaged with the holes of the blade to prevent the plug from coming off.

As shown in FIG. 16, the outlet having the above structure is connected to a mounting frame 50 which is standardized for three large polygons which is a switch or outlet standard in JIS or Japan Wiring Equipment Manufacturers Association Standard. .. That is, as described above, the case 10 has a unit size of 3 of the general wiring equipment.
Since it is formed with the mounting dimensions for one piece, the mounting frame 50 has one
Can be installed individually. The mounting frame 50 has an opening window 51.
A holding hole 53 in which the coupling claw pieces 16 projecting from the side edges of the case 10 engage with both side pieces 52a, 52b surrounding the
A side piece 52a is formed with an operation piece 54 which has a and 53b and can be bent so as to change the distance from the side piece 52a. When the case 10 is attached to the mounting frame 50, if the case 10 is pressed against the mounting frame 50 from the rear of the mounting frame 50, the operation piece 54 bends and the case 10 is pressed.
Can be fitted to the mounting frame 50, and at this time, the portion between the flanges 14 of the cover 12 is inserted into the opening window 51. on the other hand,
To remove the case 10 from the mounting frame 50, the operation piece 54 may be pryed with a driver or the like. Side piece 52 that surrounds the opening window 51
The connecting frame 55a, 55b orthogonal to a, 52b has a mounting frame 5 attached to the mounting box when the mounting box is used.
Slotted hole 56 for inserting a box screw for connecting 0,
A metal fitting insertion hole 57 into which a part of the metal fitting is inserted when performing construction using the metal fitting that sandwiches the wall panel with the mounting frame 50 is formed. Further, a screw hole 58 into which a plate screw for attaching a decorative plate that covers the front surface of the attachment frame 50 is screwed is also provided. The mounting frame shown is a synthetic resin mounting frame 50, but in the case of a metal mounting frame, the coupling claws provided on the mounting frame are inserted into the coupling holes 15a.

[0023]

According to the present invention, a pair of core halves each having a single-layer winding made of a plurality of rectangular conductors wound around a core portion,
Since the central insulating bobbin is sandwiched and is coaxially connected to both sides of the central insulating bobbin, winding can be wound around the core more easily and productivity can be improved as compared with the conventional toroidal core. Further, since the first holder is mounted across both axial end portions of the pair of core halves, and the second holder is mounted across both radial end portions thereof, Each holder squeezes both core halves inward in the axial direction and inward in the radial direction with a predetermined spring force, and the cores are strongly pressed against each other, preventing mutual displacement between the cores. , Reduce the magnetic resistance,
The inductance can be increased. Furthermore, by densely winding the rectangular conductor that constitutes the single-layer winding,
The windings themselves become dense in the axial direction, and the coil block as a whole can be made compact.

[Brief description of drawings]

FIG. 1 is a perspective view of a choke coil showing an embodiment of the present invention.

2A is a circuit diagram of the embodiment, FIG. 2B is a side view of a main portion of a choke coil used in the embodiment, and FIG. 2C is a front view of a main portion of the choke coil used in the embodiment.

FIG. 3 is an exploded perspective view of a main part of a choke coil used in an example.

FIG. 4 (a) is a schematic plan view of the core half body of the above, (b).
Is a plan view of the first holder used in the embodiment, and (c) is a plan view showing its mounting state.

FIG. 5A is a schematic side view of the core half and the vicinity of the center of the second holder, and FIG. 5B is a side view showing the mounted state.

FIG. 6A is a schematic plan view of the vicinity of both ends of the core half body and the second holder, and FIG. 6B is a side view showing a mounting state thereof.

FIG. 7 is an exploded perspective view showing a case of the embodiment.

FIG. 8 is an exploded perspective view showing the internal structure of the case of the embodiment.

FIG. 9 is a front view of a cover used in the embodiment.

FIG. 10 is a cross-sectional view of a cover used in the example.

FIG. 11 is a rear view of the body used in the embodiment.

FIG. 12 is a sectional view of a body used in an example.

FIG. 13A is a front view of one lead plate.
(B) is a side view used for an Example.

14A and 14B show a terminal plate and a blade receiving spring used in Examples, FIG. 14A being a plan view and FIG. 14B being a side view.

15A and 15B show a terminal plate and a blade receiving spring used in Examples, FIG. 15A being a plan view and FIG.

FIG. 16 is a perspective view showing an example of a mounting frame used in the embodiment.

[Explanation of symbols] 1 flat conductor 2 core half body 2a core 2b yoke 70 second holder 74 first holder 80 central insulating bobbin

Claims (1)

[Claims] 1. A single-layer winding formed by bending and winding a rectangular conductor in a width direction around a core part magnetically coupled to a yoke part and stacking the rectangular conductor in a thickness direction in an axial direction of the core part. A pair of core halves that are provided are coaxially connected to both sides of the central insulating bobbin, and straddle both axial half ends of both core halves so that both core halves face inward in the axial direction. And a first holder that presses with a predetermined spring force is mounted, and the two spring halves are extended inward in the radial direction by straddling both ends of the two core halves in the radial direction. A choke coil characterized in that a second holder for pinching by force is attached.