JPH07326518A - Inductance element - Google Patents

Abstract

PURPOSE:To obtain an inductance element with low contact resistance and desired characteristic without winding a conductor. CONSTITUTION:With the first and second terminals 6 and 16 of each corrugated conductive board 13, the first connecting piece 8 is formed into one body. Further, turning parts 9 and 19 are formed at each conductive board 13. These turning parts 9 and 19 are turned alternately from the front and rear sides of each conductive board 13, so that an air-core coil 11 wherein conductive pieces 4 and 4A and conductive boards 14 and 14A are laminated in spiral. Thus, the air-core coil 1 and 11 are obtained only by turning the conductive pieces 4 and 4A and conductive boards 14 and 14A along the turning parts 9 and 19. And, the first and second terminals 6 and 16 are formed into one body by the first connection piece 8, so that the contact resistance of the whole air-core coil 11 is reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inductance element such as a coil or transformer containing an air core or a magnetic core.

[0002]

2. Description of the Related Art In general, an inductance element typified by a coil, a transformer, or the like has a round cross-section metal wire or square cross-section metal plate as a conductive material wound around a bobbin made of resin or paper. An air-core coil is formed by rotating the core, and a core, which is a magnetic member, is inserted into the central portion of the conductor wound around the bobbin if necessary. Therefore, in the conventional manufacturing process of the inductance element, at least the work of winding the conductor is indispensable.

[0003]

SUMMARY OF THE INVENTION In the above conventional technique,
In the process of manufacturing the inductance element, the bobbin must be rotated and the conductor must be wound evenly, which requires a complicated manufacturing process. is there. On the other hand,
In the case of connecting a plurality of inductance elements obtained in this way in series, conventionally, the terminals on both sides of each inductance element are once soldered to the printed circuit board, and the electrical characteristics of each inductance element are connected via the pattern of the printed circuit board. Connection is made mutually, and in this case,
Since each of the inductances has two soldered connection portions, there is a drawback that the overall contact resistance is increased and the characteristics of each inductance element are affected.

Therefore, in view of the above problems, the present invention provides an air-core coil or a magnetic core in which desired characteristics can be obtained without winding a conductor and which has a small contact resistance even when elements are connected in series. The purpose is to provide inductance elements such as coils and transformers.

[0005]

SUMMARY OF THE INVENTION An inductance element of the present invention comprises a corrugated first and second conductive plate having conductive pieces arranged in a column, and a first conductive plate formed on the first conductive plate. 1
Is integrally formed with a first connecting piece for connecting the second terminal formed on the second conductive plate, and the folded portion is provided between the conductive pieces so that the conductive pieces are spirally stacked. Is formed. In this case, it is preferable to provide magnetic cores on the first and second air-core coils obtained by folding back the conductive pieces of the first and second conductive plates. Furthermore, a third conductive plate that insulates the conductive piece is disposed between the stacked conductive pieces of the first conductive plate, and the third conductive plate is disposed between the stacked conductive pieces of the second conductive plate. Fourth insulated from conductive piece
And a fifth conductive plate formed on the third conductive plate.
Second terminal integrally formed with the third conductive plate and the fourth conductive plate on the sixth terminal formed on the fourth conductive plate
It is preferable to provide the connecting piece.

[0006]

With the above structure, when the folded portion between the conductive pieces forming the first and second conductive plates is folded back, a pair of air core coils having desired characteristics in which the conductive pieces are spirally laminated are obtained. To be The first terminal and the second terminal of each conductive plate are the first
Since it is integrally molded by the connecting piece of, the contact resistance of this portion is eliminated.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. First, referring to FIG. 1, the structure of the conductor 2 which will be the first air-core coil 1 and the second air-core coil 11 will be described. The conductor 2 has a symmetrical first conductive plate 3 and a second conductive plate 13 formed in a corrugated shape, and the first conductive plate 3 has two types of L-shaped conductive plates. Piece 4,4A
Are arranged in a plurality of columns so that the cutouts 5 and 5A of the adjacent conductive pieces 4 and 4A face in opposite directions, and the second conductive plate 13 also has two types of conductive shapes formed in an L shape. Piece 14, 14A
Are arranged in a plurality of columns so that the cutouts 15 and 15A of the adjacent conductive pieces 14 and 14A face in opposite directions. First conductive plate 3
1. The first terminal 6 is formed on one end of the conductive piece 4 located at the upper end in FIG. 1, and the other end of the first conductive plate 3, that is, the conductive piece located at the lower end in FIG. A third terminal 7 is formed at the end of 4 for electrical connection with the outside. Similarly, the second terminal 16 is formed also on the conductive piece 14 located at one end of the second conductive plate 13, and at the end of the conductive piece 14 located at the other end of the second conductive plate 13. Also, a fourth terminal 17 is formed that enables electrical connection with the outside. A first connecting piece 8 integrally formed with each of the conductive plates 3 and 13 is provided between the first terminal 6 and the second terminal 16 forming each of the conductive plates 3 and 13. The piece 8 connects the first terminal 6 and the second terminal 16 of the conductive plates 3 and 13 to each other. Further, folded portions 9 are formed between the conductive pieces 4 and 4A and between the conductive piece 4 and the first terminal 6, respectively, and also between the conductive pieces 14 and 14A and between the conductive piece 14 and the second terminal 16. Similarly, the folded-back portion 19 is formed. And
When the folded portion 9 is alternately folded from the front side and the back side of the first conductive plate 3, the air-core coil 1 in which the conductive pieces 4 and 4A are laminated in a spiral shape is obtained, and the conductive piece cut out in an L shape is formed. The notch portions 5 and 5A of 4, 4A are arranged to face each other when the conductive pieces 4 and 4A are stacked, so that the center portion of the air-core coil 1 surrounded by the notch portions 5 and 5A can be arranged as shown in FIG. A prismatic cavity 10 as shown is formed. Similarly, when the folded portion 19 is alternately folded from the front side and the back side of the second conductive plate 13, the air-core coil 11 in which the conductive pieces 14 and 14A are spirally stacked is obtained and the L-shaped notch is formed. The cutout portions 15 and 15A of the formed conductive pieces 14 and 14A are arranged so as to face each other when the conductive pieces 14 and 14A are stacked, and thereby the central portion of the air-core coil 11 surrounded by the cutout portions 15 and 15A. Also, Fig. 6
A prismatic cavity 30 is formed as shown in FIG.

In FIG. 1, the conductor 2 is obtained by subjecting a conductive metal plate typified by copper or brass to mechanical processing such as punching (pressing) or wire cutting. In this example, a copper plate having a thickness of 0.08 mm is used as the conductor 2.
The shapes of the conductive pieces 4, 4A and the conductive pieces 14, 14A are L
The shape is not limited to the letter shape, and may be formed in a U shape or a V shape. If the conductive pieces 4, 4A and the conductive pieces 14, 14A are formed in a U shape, the hollow portions 10, 30 of the air core coils 1, 11 can be formed in a cylindrical shape. In addition, the conductive piece 4, 4A or the conductive piece
The outer surface of 14, 14A is formed in a U shape, and the inner notch 5,
5A or notches 15 and 15A in V shape, or conversely,
The outer surfaces of the conductive pieces 4, 4A or the conductive pieces 14, 14A are formed in a V shape, and the inside cutouts 5, 5A or cutouts 15,
The 15A can also be U-shaped. Such a modification may be appropriately adopted depending on the space for housing the air-core coils 1 and 11 and the shape of the magnetic core described later.

From the conductor 2 in this embodiment, four conductors are provided.
Air core coils 1 and 11 of turns are obtained. The number of turns of each air core coil 1 and 11 can be arbitrarily changed according to the number of conductive pieces 4 and 4A or conductive pieces 14 and 14A.
The n-turn air core coils 1 and 11 are obtained from the conductive pieces 4 and 14 and the n-1 conductive pieces 4A and 14A. Further, it is possible to easily form the air-core coils 1 and 11 having different numbers of turns.

When manufacturing the air-core coils 1 and 11 having the above-described structure, first, a conductive metal plate is processed into a shape shown in FIG. 1 by a mechanical method such as pressing or wire cutting. In the step of forming the conductor 2, only the metal plate is machined into a predetermined shape of the conductor 2,
There is no need for complicated work such as winding the conductor evenly as in the conventional case. Next, when the folded portions 9 and 19 are alternately folded from the front side and the back side of the first and second conductive plates 3 and 13, the conductive pieces 4 and 4A and the conductive pieces 14 and 14A are sequentially laminated in a spiral shape, Is a substantially rectangular air-core coil 1,
You get 11. Even in the step of folding back the conductive plates 3 and 13,
Only by bending the first and second conductive plates 3 and 13 with respect to the predetermined folded-back portions 9 and 19, the work can be performed subsequent to the step of forming the conductor 2.
Then, the air-core coils 1 and 11 thus obtained are
It can be used as an inductance element having a predetermined inductance characteristic.

The air-core coils 1 and 11 which are the inductance elements thus obtained are connected in series by the connecting portion 8. The air-core coils 1 and 11 have the first terminal 6 and the second core 6 respectively.
Since the terminal 16 is already electrically connected by the connecting portion 8 in the process of manufacturing the air-core coils 1 and 11, the third terminal 7 and the fourth terminal 17 are simply soldered to the outside. Good. That is, the first terminal 6 of each air core coil 1, 11
Since the second terminal 16 and the second terminal 16 are integrally molded by the first connecting piece 8, there is no contact resistance in this portion, and conventionally there are four soldered connection terminals for the air core coils 1 and 11. It is possible to reduce the contact resistance of the entire air-core coils 1 and 11 as compared with the above.

Next, the structure of various inductance elements obtained by using the conductor 2 in FIG. 1 will be described. 2 and 3 show the shape of the magnetic core 41 provided for each of the air-core coils 1 and 11, and in FIG. 2, the magnetic core 41 is a pair of upper and lower magnetic members whose sides are E-shaped.
42, 43, the central portion 44 of each magnetic member 42, 43 is erected so that the hollow portions 10, 30 can be inserted. A groove 46 is formed between the central portion 44 and the side wall 45.
Conductive pieces 4, 4A or conductive pieces 14, 14A are arranged along 46. Then, the conductor 2 in FIG. 1 is formed in the two air-core coils 1 and 11 by the above-described manufacturing method, and the hollow cores 10 and 30 of the air-core coils 1 and 11 have central portions of the magnetic members 42 and 43, respectively. When both magnetic members 42 and 43 are attached and fixed while inserting 44, the two choke coils 37 and 47 shown in FIG.
An inductance element in which are connected in series is obtained.

Also in the choke coils 37 and 47 obtained by the air core coils 1 and 11 and the two magnetic cores 41, the number of soldering connection terminals is the same as in the case of the air core coils 1 and 11 alone. By reducing the number, it becomes possible to reduce the contact resistance of the choke coils 37 and 47 as a whole. In this case, the magnetic core 41
The shape is not limited to the combination of the E-shaped magnetic members 42 and 43, and various types can be applied.

On the other hand, FIG. 5 shows a conductor 52 which constitutes the secondary side of transformers 51 and 61 which will be described later. In the figure,
The conductor 52 has a U-shaped third conductor 53 and a fourth conductor 63 having the same shape as the third conductor 53. The third conductor plate 53 and the fourth conductor 63 have the same shape. A fifth terminal 54 and a sixth terminal 64, and a seventh terminal 55 and an eighth terminal 65 are integrally formed on both ends of the conductive plate 63, respectively. Also, the fifth terminal 54
And the sixth terminal 64, a protruding center tap terminal 56 integrally molded with the third conductive plate 53 and the fourth conductive plate 63 is formed.
A second connecting piece 57 having is provided. Each of the third and fourth conductive plates 53, 63 has a magnetic member 4 that constitutes the magnetic core 41.
The first conductive plate 3 is formed so that it can be inserted into the groove portions 46 of 2, 43.
Between the laminated conductive pieces 4 and 4A and the second conductive plate 13
Are provided between the laminated conductive pieces 14 and 14A, and the conductive pieces 4 and 4A and the conductive pieces 14 and 4A constituting the air-core coils 1 and 11
Insulating layers such as plastic films (not shown) on both sides of the conductive plates 53, 63 to avoid electrical contact with the 14A.
Is formed.

Then, the conductor 2 in FIG. 1 is formed into two air-core coils 1 and 11 by the above-mentioned manufacturing method, and the magnetic members 42 and 43 are provided in the hollow portions 10 and 30 of the air-core coils 1 and 11, respectively. While inserting the central portion 44 of the above, and interposing the third conductive plate 53 and the fourth conductive plate 63 between the conductive pieces 4 and 4A and between the conductive pieces 14 and 14A, both magnetic members 42 and 43 are When mounted and fixed, the two transformers 51, 61 shown in FIG.
An inductance element in which are connected in series is obtained. In this case, the air core coils 1 and 11 constitute the primary side of the transformers 51 and 61, and the circuit diagram of the inductance element shown in FIG. 7 is as shown in FIG. This is especially suitable for the transformers 51 and 61 of the two-transformer partial resonance type converter,
By appropriately changing the numbers of the conductive pieces 4 and 4A of the air-core coil 1 and the conductive pieces 14 and 14A of the air-core coil 11, an arbitrary voltage proportional to the primary-side air-core coils 1 and 11 can be applied to the secondary side. It can be taken out from the plates 53 and 63. Also transformer 5
On the primary side of 1, 61, since the first terminal 6 and the second terminal 16 of each air-core coil 1, 11 are integrally molded by the first connecting piece 8, the contact resistance of this portion disappears, It goes without saying that the contact resistance on the primary side of the transformers 51, 61 can be made smaller than in the conventional case, but also on the secondary side of the transformers 51, 61, the fifth terminals of the third and fourth conductive plates 53, 63. Since the 54 and the sixth terminal 64 are integrally molded by the second connecting piece 67, the contact resistance at this portion is eliminated, and the contact resistance on the secondary side of the transformers 51 and 61 can be simultaneously reduced as compared with the conventional case.

A plurality of third conductive plates 53 and fourth conductive plates 63 can be provided. In this case, a plurality of conductive plates 53, 63 are connected to the terminals 54, 55 or the terminals 64, 65, and the conductive plates 53, 63 are connected between the conductive pieces 4, 4A and the conductive pieces.
It is preferable to interpose between 14 and 14A. Further, if the above-mentioned choke coil 47 is configured without providing the one conductive plate 63, an inductance element in which the transformer 51 and the choke coil 47 are connected in series can be obtained. In this way, the magnetic core 41
And the conductive plates 53 and 63 are selectively provided, the air core coils 1 and 11, the choke coils 37 and 47, the transformer 51,
Various types of inductance elements can be constructed by combining 61 types.

As described above, in this embodiment, as shown in FIG. 1, the corrugated shape is obtained by arranging the conductive pieces 4 and 4A and the conductive pieces 14 and 14A in tandem in accordance with claim 1. The first conductive plate 3 and the second conductive plate 13 are connected to the first terminal 6 formed on the first conductive plate 3 and the second terminal 16 formed on the second conductive plate 13. Integrally formed with the first connecting piece 8,
The conductive pieces 4, 4A and the conductive pieces 14, 14 are stacked so that the conductive pieces 4, 4A and the conductive pieces 14, 14A are spirally stacked.
The folded portions 9 and 19 are formed between A. Therefore, in this case, the obtained air-core coils 1 and 11 do not have any wound portion of the conductor as in the conventional case, and are different from the integrally molded conductor plates 3 and 13 and the connecting portion 8. Then, by simply folding back the folding portions 9 and 19, the conductive pieces 4 and 4A and the conductive pieces 14 and 14A have desired characteristics of being spirally laminated, and the air-core coils 1 and 11 connected in series as an inductance element. Can be obtained. Moreover, the air core coil 1,
The first terminal 6 and the second terminal 16 of 11 are the first connecting piece 8
As a result, the contact resistance at this portion is eliminated, and as a result, the contact resistance can be reduced even when the air core coils 1 and 11 are connected in series.

Further, in this embodiment, in accordance with claim 2,
The conductive pieces 4, 4A of the first conductive plate 3 and the second conductive plate 13
By providing the magnetic core 41 to the first and second air-core coils 1 and 11 obtained by folding back the conductive pieces 14 and 14A, choke coils 37 and 47 as inductance elements having desired characteristics are obtained. Can choke coil
Even though 37 and 47 are connected in series, the contact resistance can be reduced.

In the present embodiment, in accordance with claim 3, a third conductive plate 53, which is insulated from the conductive pieces 4 and 4A, is arranged between the conductive pieces 4 and 4A stacked on the first conductive plate 3. In addition to the above, a fourth conductive plate 63 that insulates the conductive pieces 14 and 14A from each other is disposed between the stacked conductive pieces 14 and 14A of the second conductive plate 13.
The fifth terminal 54 formed on the third conductive plate 53 and the sixth terminal 64 formed on the fourth conductive plate 63 are integrally molded with the third conductive plate 53 and the fourth conductive plate 63. Since the second connecting piece 57 is provided, the transformers 51 and 61 as the inductance elements having desired characteristics can be obtained, and the transformers 51 and 61 are connected in series. It is possible to simultaneously reduce the contact resistance on the primary side and the secondary side. Further, the transformers 51 and 61 obtained from the third aspect are suitable for a two-transformer type inverter transformer which constitutes a partial resonance type converter.

As is apparent from the above-mentioned embodiment, the choke coil 37,
A coil containing the magnetic core 41 in which 47 is connected in series can be easily obtained, and the transformers 51 and 61 can be obtained only by providing the third conductive plate 53 and the fourth conductive plate 63 for this coil.
Therefore, various inductance elements can be obtained from the air core coils 1 and 11, and the application range thereof is extremely wide.

The present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention.

[0022]

According to the inductance element of the first aspect of the present invention, the wave-shaped first and second conductive plates are formed by arranging the conductive pieces in a column, and the first terminal is formed on the first conductive plate. And a first connecting piece for connecting the second terminal formed on the second conductive plate are integrally formed, and a folded portion is formed between the conductive pieces so that the conductive pieces are stacked in a spiral shape. The desired characteristics can be obtained without winding the conductor, and an air-core coil having a small contact resistance can be obtained even when the elements are connected in series.

The inductance element according to claim 2 is
The first and second air-core coils obtained by folding back the conductive pieces of the first and second conductive plates are provided with magnetic cores, and desired characteristics can be obtained without winding a conductor. An air-core coil having a small contact resistance can be obtained even when the elements are connected in series.

The inductance element according to claim 3 is
A third conductive plate is provided between the stacked conductive pieces of the first conductive plate to insulate the conductive piece, and the conductive piece is sandwiched between the stacked conductive pieces of the second conductive plate. A fourth conductive plate that is insulated from the fourth conductive plate, and a fifth terminal that is formed on the third conductive plate and a sixth terminal that is formed on the fourth conductive plate.
Is provided with a second connecting piece integrally formed with the third conductive plate and the fourth conductive plate, and desired characteristics can be obtained without winding a conductor, and an element Even in the case of connecting in series, a transformer with small contact resistance can be obtained at the same time on the primary side and the secondary side.

[Brief description of drawings]

FIG. 1 is a front view of a conductor showing an embodiment of the present invention.

FIG. 2 is a front view of a magnetic material forming the same magnetic core.

FIG. 3 is a side view of a magnetic material forming the same magnetic core.

FIG. 4 is a perspective view of the above choke coil.

FIG. 5 is a front view of a conductor forming a secondary side of the transformer.

FIG. 6 is an exploded perspective view of the same transformer.

FIG. 7 is a perspective view of the same transformer.

FIG. 8 is a circuit diagram of the same transformer.

[Explanation of symbols]

 3 1st conductive plate 4, 4A, 14, 14A conductive piece 6 1st terminal 8 1st connecting piece 9, 19 Folding part 13 2nd conductive plate 16 2nd terminal 41 Magnetic core 53 3rd conductive Plate 54 Fifth terminal 57 Second connecting piece 63 Fourth conductive plate 64 Sixth terminal

Claims (3)

[Claims] 1. A corrugated first and second conductive plate in which conductive pieces are arranged in a row, a first terminal formed on the first conductive plate and the second conductive plate. An inductance element characterized by integrally forming a first connecting piece for connecting the formed second terminal, and forming a folded-back portion between the conductive pieces so that the conductive pieces are spirally stacked. . 2. The inductance element according to claim 1, wherein the first and second air-core coils obtained by folding back the conductive pieces of the first and second conductive plates are provided with magnetic cores. . 3. A conductive piece having a third conductive plate that is insulated from the conductive piece, the conductive piece being stacked between the first conductive plates, and the conductive piece being stacked with the second conductive plate. A fourth conductive plate that is insulated from the conductive piece is disposed between the third conductive plate and the third conductive plate.
A second connecting piece integrally formed with the third conductive plate and the fourth conductive plate on the fifth terminal formed on the conductive plate and the sixth terminal formed on the fourth conductive plate. The inductance element according to claim 2, wherein the inductance element is provided.