JPH08316059A - Thin transformer - Google Patents

Abstract

PURPOSE: To provide a thin transformer being employed in electric apparatus in which the insulation properties, performance and characteristics are enhanced at low price. CONSTITUTION: A winding 2, relative position of which can not be determined independently, is set on a planar coil spacer 5 comprising ribs 6a and protrusions 6b of predetermined width and height formed at least on the inner and outer circumferential end faces. The coil spacer 5 and the winding 2 are paired and laminated sequentially to produce a laminated coil where the winding is contained in a recess defined by the ribs 6a and protrusions 6b on the coil spacer 5. This structure ensures the mutual distances between the windings and between the winding and the core stably thus realizing an inexpensive thin transformer stabilized in view point of insulation and performance.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin transformer using a laminated coil used in various electronic devices.

[0002]

2. Description of the Related Art In recent years, transformers meet the needs of higher frequency, smaller size, and thinner type, and a printed coil laminated transformer using a print etching technique, a transformer having a punched coil laminated structure formed by punching a copper plate,
Alternatively, a transformer having a spiral coil laminated structure in which electric wires are formed in a spiral shape has been developed.

In reality, in addition to the above technical needs, there is a strong demand for thorough cost reduction and safety improvement as a background of the times, and without this point, practical use is not possible. ing.

However, in consideration of cost and versatility, the printed coil produced by the etching method has a high current cost and the current capacity is limited in terms of increasing the film thickness. It becomes necessary to adopt a transformer having a spiral coil laminated structure formed in the above.

Further, demands for thinning and cost reduction of power supply devices are also increasing, and it is no exaggeration to say that the key part for differentiation is a transformer.

A conventional thin transformer using a laminated coil will be described with reference to FIGS. In the figure, 1 is a magnetic core, 2 is a winding wire, 3 is an insulating paper, and 4 is a coil case.

The structure will be described in more detail with reference to FIG. 11. After winding a wire 2 formed by spirally winding an electric wire alone and insulating paper 3 are alternately laminated, a laminated coil is completed. The thin transformer main body is completed by incorporating the magnetic core 1 forming the closed magnetic circuit from the direction in which the coils are stacked. The winding 2 may be a punched coil made by punching a thin plate conductor. In addition,
In this conventional example, two sets of windings 2 are alternately laminated, but the same applies to two or more sets as long as the transformer has a primary winding and a secondary winding. 3 winding 2 in FIG.
FIG. 4 shows a cross-sectional view of a thin transformer in which layers are stacked. Figure 10
In this case, two sets of primary windings 2a are used and are alternately laminated with the secondary windings 2b. Further, FIG. 9 shows a cross-sectional view of a thin transformer using a coil case 4 as another conventional technique. Here, the primary winding 2a, the secondary winding 2b, and the insulating paper 3 are laminated in the coil case 4, and then the magnetic core 1 is incorporated to complete the thin transformer main body.

[0008]

However, in the conventional thin transformer of FIG. 10 described above, since the primary winding 2a and the secondary winding 2b are spirally wound by each coil alone, Since it is a winding whose relative position is not determined by itself with respect to the other windings or the magnetic core 1 and has no means for determining the position between the primary winding 2a and the secondary winding 2b, Insulation failure due to insufficient distance occurs in the portion A in the figure, and variations in electrical performance also occur, resulting in a loss in quality.

Moreover, the primary winding 2a or the secondary winding 2
Since there is also no means for determining the position between b and the magnetic core 1, insulation failure due to insufficient distance may occur at the portion B in the figure, resulting in a larger quality loss.

As a method of remedying such a problem as much as possible, a method has been proposed in which a laminated coil is placed in a coil case 4 to maintain insulation as shown in FIG. Since the position is not determined, it is difficult to secure insulation at the portion A1 in the figure, and the quality loss due to the variation in electrical performance is the same as in the case of FIG.

As described above, when a winding whose position is not determined relative to another winding or the magnetic core is used alone, even if a thin plate-shaped winding which is expected to be low in cost due to the construction method is used If there is no means for determining the mutual positional relationship between the winding and the magnetic core, insulation problems, performance problems, etc. will occur, which will be a major obstacle to practical use.

The present invention is intended to solve the above-mentioned problems. Even when a winding whose position is not fixed relative to another winding or a magnetic core is used independently, such as a spiral coil or a punched coil, it is possible to reduce the interwinding and By showing the means for determining the mutual positional relationship between the winding and the magnetic core, the problem of insulation and the problem of performance are eliminated, and a thin transformer with improved safety is provided at low cost.

[0013]

In order to solve the above-mentioned problems, the present invention is a laminated coil having one or more wire loops, wherein a convex portion having a predetermined width and height is formed on at least a part of the inner and outer peripheral end faces. The above winding is housed on a flat plate-shaped coil spacer formed by, and the coil spacer and the winding are sequentially laminated as a pair to form a laminated coil, and a magnetic core forming a closed magnetic circuit from the direction in which the coil is laminated. Is built in.

[0014]

With the above structure, since the windings are stacked in the recessed portion of the flat plate-shaped coil spacer, that is, in a fixed position, the distances between the windings and between the windings and the magnetic core are stably secured. This makes it possible to maintain and stabilize performance easily.

[0015]

【Example】

(Embodiment 1) A first embodiment, which is an embodiment of the present invention, will be described below with reference to FIGS.

FIG. 1 is an exploded perspective view for explaining a laminated structure of a thin transformer showing a first embodiment of the present invention, and FIG. 2 is a sectional view of a thin transformer showing a first embodiment of the present invention. FIG. 3 is a plan view of a thin plate coil for supplementarily explaining the first embodiment of the present invention. 1 to 3, the same parts as those of the prior art are denoted by the same reference numerals, detailed description thereof will be omitted, and only different points will be described. At least a part of the inner and outer peripheral end faces has a rib having a predetermined width and height. 6a and the convex part 6b are formed, and the flat coil spacer 5 is used.

The structure will be described in more detail with reference to FIGS. 1 and 2. A winding 2 formed by spirally winding an electric wire alone has a predetermined width and height on at least a part of the inner and outer peripheral end faces. The ribs 6a and the protrusions 6b are formed on the flat plate-shaped coil spacer 5. At this time, the winding 2 is constituted by a winding whose position is not fixed relative to other windings or the magnetic core by itself, but the position is changed depending on the widths of the ribs 6a and the convex portions 6b provided on the flat coil spacer 5. It is regulated, and as a result, it is accommodated in the concave portion formed by the rib 6a and the convex portion 6b of the coil spacer 5, and the winding 2 can be accommodated in a fixed position. Further, in this embodiment, the position of the lead wire of the winding wire 2 can be regulated by the convex portion 6b, and the lead wire processing at the time of mounting becomes easy.

Next, a pair of the coil spacer 5 and the winding 2 is laminated so as to sandwich the insulating paper 3 between the layers, and the insulating paper 3 is inserted also in the lowermost layer and the uppermost layer to form a laminated coil. After completing the above, the thin transformer main body is completed by incorporating the E-shaped magnetic core 1 forming the closed magnetic circuit from the direction in which the coils are laminated.

When a laminated coil is manufactured by using the coil spacer 5 and the winding 2 as a pair in this manner, since the windings 2 whose positions are not originally determined by themselves are all laminated in a fixed position, the laminated coil is formed. When completed, the mutual distances between the windings 2 and between the windings 2 and the magnetic core 1 (dimensions W ₁ and W ₂ in FIG. 2) can be secured stably.

In the above description, the coil spacer 5 and the winding 2 are paired, and the insulating paper 3 is sandwiched between the layers, but in the process of manufacturing, the insulating paper 3 is sequentially arranged from the bottom of FIG. The coil spacer 5, the winding 2, the insulating paper 3, the coil spacer 5, the winding 2, and the insulating paper 3 may be laminated in this order.

As described above, according to the configuration shown in FIGS.
Stable distance between windings and between windings and magnetic cores is secured, even if the windings or punching method alone does not determine the relative position with other windings or magnetic cores. It is possible to solve the problems of insulation and performance, it is not necessary to use an expensive printed coil using etching method, printing, vapor deposition, etc., it is inexpensive and versatile in current capacity etc. The thin laminated coil can be manufactured, and the thin transformer using the high quality laminated coil with improved safety can be provided at a low cost.

When using a coil or the like in which the thin plate-shaped coil 2c is positioned by the insulating paper 3 as shown in FIGS. 3 (a) and 3 (b), it is not necessary to use a pair with the coil spacer 5 of the present invention. However, when used in combination with the laminated coil shown in the first embodiment of the present invention (when either the primary winding or the secondary winding is of the winding type or the punching type), the effect of the present invention is Is what you get.

(Embodiment 2) Further, in the first embodiment, although the method for producing the spiral coil for forming the single coil is not explained, the insulation coated electric wire is used to spirally wind the coil. In the next step, a method of fixing with an adhesive, a fusing material, a resin or the like so that the shape can be maintained, and a method of forming a wire with a self-fusing layer and an insulating coating layer in a spiral shape are conceivable. . In the latter case, since a single coil whose shape can be maintained at the same time as the winding is formed, the winding fixing step for maintaining the winding shape can be omitted.

That is, if the electric wire with the self-bonding layer and the insulating coating layer is spirally wound as the winding 2 whose position is not fixed relative to other windings or the magnetic core, the spiral coil is wound. There is also a unique effect that the winding fixing step for maintaining the linear shape can be eliminated.

(Embodiment 3) A third embodiment of the present invention will be described below with reference to FIG.

In FIG. 4, the difference from the first embodiment of FIG. 1 is that while a predetermined insulating paper 3 is inserted so that the insulation between the primary and secondary has a three-layer insulation structure, the layers are sequentially laminated. Is that the laminated coil is constituted by

According to this structure, the thickness between the primary winding and the secondary winding has a withstand voltage structure of three-layer insulation.
If the withstand voltage test based on the safety standard of each country is satisfied, the thickness is not required and the insulation thickness can be reduced. This also improves the coupling between the primary and secondary windings, resulting in new effects of loss reduction and improved control performance. Regarding the creepage distance, if the widths W ₁ and W ₂ of the ribs 6a and the width W ₃ of the convex portions 6b of the coil spacer 5 are appropriately set in accordance with the regulations, the winding 2 will be the coil spacer 5.
Since it fits in the recessed part, it is possible to easily secure the creepage distance based on the safety standard, and it is possible to provide a thin transformer that can surely comply with the safety standards of each country together with the above-mentioned thickness. Is also obtained.

(Fourth Embodiment) A fourth embodiment of the present invention will be described below with reference to FIG.

In the figure, the difference from the thin transformer of FIG. 1 is that a film having a thickness that does not allow pinholes is thermoformed to form a thermoformed coil spacer 5a.

Since the thermoformed coil spacer 5a has no pinhole and can be made extremely thin, it can also serve as the insulating paper 3, and the insulating paper 3 between the primary and secondary can be used.
There is a new effect that the number of used sheets can be reduced.
Furthermore, since the insulation thickness between the primary and secondary can be reduced,
The coupling between the secondary and secondary windings is also improved, and great effects can be obtained in terms of loss reduction, control performance improvement, and thinning.

(Fifth Embodiment) A fifth embodiment of the present invention will be described below with reference to FIGS. 6, 7A and 7B.

The difference between FIG. 1 and FIG. 1 is that
The point is that the laminated coil is housed in the case 4 and the filling resin 7 is filled therein.

According to the structure shown in FIG. 6, since the laminated coil whose position is predetermined is housed, there is no problem with the insulation distance, but the positions of the case 4 and the coil spacer 5 are as shown in FIG. If the matching is performed, the relative position of the laminated coil is determined in the case 4, and the filling resin 7 can be sufficiently permeated.

In FIG. 7 (a), the tapered alignment portion C is the portion that determines the relative position.
The alignment portion C may have a stepped shape as shown in FIG. If the filling resin 7 is filled by a method such as casting in this state, the filling resin 7 is filled in the laminated coil composed of the winding wire 2 in a state where the relative position is determined, and the electrical insulation is further strengthened. It

Further, since the heat conduction is improved by encapsulating the resin, the heat generation of the transformer can be reduced, and a new effect of miniaturization can be obtained. Furthermore, the filling resin 7
If the voids of the filling resin 7 are removed by using a vacuum casting method or the like when casting, the insulation distance in accordance with the safety standard is relaxed, so that a drastic downsizing can be achieved. The effect is also obtained.

(Sixth Embodiment) A sixth embodiment of the present invention will be described below with reference to FIG.

The thin transformer shown in FIG. 8 differs from that shown in FIG. 1 in that the laminated coil including the winding wire 2 is vacuum-molded with the molding resin 8.

If the resin is to be filled by the molding method, the movement and positioning of the coil in the mold usually becomes a problem.
However, in the present invention, since the winding 2 and the coil spacer 5 are integrally laminated, the individual coils do not move, and the inner and outer peripheral portions or the lead-out portions of the laminated coil are used to make the mold. Since the positioning inside can be performed, the molding method can be performed.

According to the structure shown in FIG. 8, since the molding resin 8 can be molded on the laminated coil including the winding 2 by the molding method, the case 4 can be removed as compared with the casting method, and the material cost can be reduced. The new effect of being able to do this is also obtained.

Further, since the molding resin 8 improves the heat conduction, the heat generation of the transformer can be reduced and the effect of miniaturization can be obtained. Furthermore, if this molding is performed by vacuum molding, the voids of the molding resin 8 can be removed. In addition, it is possible to obtain the effect peculiar to the present embodiment that the insulation distance according to the safety standard is relaxed and the size can be dramatically reduced.

[0041]

INDUSTRIAL APPLICABILITY As described above, the present invention is a laminated coil having at least one coil having at least one winding whose position is not fixed relative to other windings or magnetic cores independently, and at least a part of the inner and outer peripheral end faces. The winding is housed on a flat plate-shaped coil spacer formed by forming ribs or protrusions having a predetermined width and height, and the coil spacer and the winding are sequentially laminated as a pair to form a laminated coil. Since the magnetic core that forms a closed magnetic circuit is built in from the direction in which the coils are stacked, (1) A winding method or a punching method is used alone, which does not determine the relative position with other windings or the magnetic core. Even if there is, the distances between the windings and between the windings and the magnetic core can be stably secured.

(2) Lead wiring processing is also facilitated. (3) The problem of insulation and the problem of performance are eliminated.

(4) An inexpensive winding can be used without using an expensive printed coil. (5) A highly safe thin transformer can be provided at low cost.

In addition, as the winding 2 whose relative position to other windings or the magnetic core is not determined independently, a winding formed by spirally winding an electric wire with a self-fusion layer and an insulating coating layer is 6) The winding fixing process for maintaining the winding shape can be eliminated.

Further, in the case where the laminated coil is constructed by sequentially laminating a predetermined insulating paper so that the insulation between the primary and secondary has a three-layer insulation structure, (7) We can provide a thin transformer that can reliably meet the safety standards of each country.

Further, in the case of using a thermoformed coil spacer by thermoforming a film having a thickness that does not allow pinholes, (8) the number of sheets of insulating paper between the primary and secondary is reduced. it can.

(9) A great effect can be obtained in terms of loss reduction, control performance improvement, and thinning. Further, in the case where the laminated coil is housed in the case and filled with resin, (10) the insulation can be strengthened, the heat generation of the transformer can be reduced, and the size can be reduced.

Further, in the case where the laminated coil is vacuum-formed with the molding resin, the case can be removed as compared with (11) the casting method, so that the material cost can be reduced.

(12) The voids of the resin can be removed, and the insulation distance according to the safety standard can be relaxed. (13) A dramatic miniaturization can be achieved.

The above effect can also be obtained. INDUSTRIAL APPLICABILITY As described above, the present invention provides high safety without insulation and performance problems.
A small and thin transformer can be provided at low cost.

By using the thin transformer of the present invention in a power supply device, (14) the power supply device can be differentiated by cost and thinning.

[Brief description of drawings]

FIG. 1 is an exploded perspective view of a thin transformer according to a first embodiment of the present invention.

FIG. 2 is a sectional view of the same.

FIG. 3 is a plan view of a thin plate coil, which is the main part of the same.

FIG. 4 is an exploded perspective view of the third embodiment.

FIG. 5 is an explanatory view explaining a state of the laminated coil of the fourth embodiment.

FIG. 6 is a sectional view of the fifth embodiment.

FIG. 7 is a partially enlarged cross-sectional view illustrating a positioning state of a coil case and a coil spacer, which is a main part of the fifth embodiment.

FIG. 8 is a sectional view of the sixth embodiment.

FIG. 9 is a sectional view of a conventional thin transformer.

FIG. 10 is a sectional view of another conventional thin transformer.

FIG. 11 is an exploded perspective view of the same.

[Explanation of symbols]

 1 Magnetic Core 2 Winding 2a Primary Winding 2b Secondary Winding 2c Thin Plate Coil 3 Insulating Paper 4 Coil Case 4a Continuous Insulating Film 4b Individual Insulating Film 5 Coil Spacer 5a Thermoformed Coil Spacer 6a Rib 6b Convex 7 Filling Resin 8 molding resin

Claims (6)

[Claims] 1. A laminated coil having at least one coil having windings, the flat coil spacer having ribs or protrusions having a predetermined width and height formed on at least a part of the inner and outer peripheral end faces. The above winding is housed above, and the coil spacer and the winding are paired in sequence to form a laminated coil.
A thin transformer incorporating a magnetic core forming a closed magnetic circuit from the direction in which the coils are stacked. 2. The thin transformer according to claim 1, wherein a single coil formed by spirally winding an electric wire with a self-fusion layer and an insulating coating layer is used. 3. The thin transformer according to claim 1, wherein a laminated coil is constructed by sequentially laminating a predetermined insulating paper while inserting a predetermined insulating paper so that primary and secondary insulation have a three-layer insulation structure. 4. The thin transformer according to claim 1, wherein the coil spacer is formed by thermoforming a film having a thickness that does not allow pinholes. 5. The thin transformer according to claim 1, wherein the laminated coil is housed in a case and filled with resin. 6. The thin transformer according to claim 1, wherein the laminated coil is formed by vacuum molding a resin.