JPH09205023A - Choke coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To contrive to thin and make a large current by a method wherein at least a terminal provided in an inner peripheral part of an air-core coil among terminals connecting with both end parts of a plate-like conductor of the air-core coil is led out outwardly through a notch or an opening provided in at least either of common magnetic legs of a closed magnetic path magnetic core. SOLUTION: A terminal pedestal 24 is incorporated into an empty core coil 20, terminals 22, 23 are incorporated so as to bend along terminal grooves 30, 31 of the terminal pedestal 24, E-type magnetic cores 33 are incorporated from above and below, a triangle member 26 of the terminal pedestal 24 is inlaid in a notch part 37 of the one E-type magnetic core 33 and positioned, and both the E-type magnetic cores 33 are coupled, whereby a choke coil leading out the terminals 22, 23 in the same direction is structured. At this time, if a height of a central magnetic leg 34 is lower than that of both outside magnetic legs 35 of the E-type magnetic cores 33, the choke coil having a magnetic gap in the central magnetic leg 34 is comprised, so that electric overlapping characteristics can be improved. Further, only the air-core coil 20 resides between the closed magnetic path magnetic core 32 and a common magnetic leg 36 to enable a higher space factor.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a choke coil used for consumer or industrial electronic equipment.

[0002]

2. Description of the Related Art A conventional thin choke coil will be described with reference to FIGS. 42 is an exploded perspective view, FIG. 43 is a perspective view showing a state where a coil is incorporated in a closed magnetic circuit magnetic core, FIG. 44 is a perspective view of a finished product, FIG. 45 is a sectional view, and FIG. 46 is a state in which one magnetic core is removed. It is a top view. In FIG.
Is a rectangular insulated conductive wire, 2 is an air-core coil, 3 is an inner peripheral portion of the air-core coil 2, 4 is a coil outer peripheral portion, 5 is an inner peripheral terminal, 6 is an outer peripheral terminal, 7 is a central magnetic leg, and 8 is an outer side. A magnetic leg, 9 is a common magnetic leg, 10 is a closed magnetic circuit magnetic core, 12 is a window height of the closed magnetic circuit magnetic core 10, and the rectangular insulated conductor 1 is spirally wound to form an air-core coil 2. Inner peripheral terminal 5 on peripheral part 3
Further, the terminal 6 of the outer peripheral portion is connected to the outer peripheral portion 4 by soldering or the like, and the air-core coil 2 and the insulating paper 11 are attached to the central magnetic leg 7 of the closed magnetic circuit magnetic core 10.

[0003]

However, in the above-mentioned conventional configuration, the terminal 5 of the inner peripheral portion is connected to the inner peripheral portion 3 of the air-core coil 2, and the common magnetic leg 9 of the air-core coil 2 and the closed magnetic path core 10 is connected. Since it is drawn out from between, the thickness of the terminal 5 on the inner peripheral portion is added to the window height 12 of the closed magnetic circuit core 10, and a dead space is generated in the direction of the window height 12 so that the space factor is reduced, and the thickness of the choke coil is reduced. There was a problem of difficulty.

Further, since the terminal 5 on the inner peripheral portion is drawn out between the air-core coil 2 and the common magnetic leg 9 of the closed magnetic circuit magnetic core 10, the cross-sectional area of the terminal cannot be increased, and the terminal is thin and can handle a large current. There was a problem that a choke coil could not be made.

An object of the present invention is to reduce the height of the choke coil and to reduce the thickness and increase the current.

[0006]

In order to solve this problem, a choke coil according to the present invention comprises a closed magnetic circuit magnetic core having a central magnetic leg, an outer magnetic leg and a common magnetic leg, and the central magnetic leg of the closed magnetic circuit magnetic core. Install an air-core coil made by spirally winding a flat conductor wire made of rectangular conductor wire or foil conductor wire, and install it on at least the inner circumference of the air-core coil among the terminals connected to both ends of the plate conductor wire of this air-core coil. The terminal is drawn to the outside through a notch or an opening provided in at least one of the common magnetic legs of the closed magnetic circuit core.

With the above structure, the inner peripheral terminal provided on the inner circumference of the air-core coil is pulled out to the outside through the notch or the opening provided on one of the common magnetic legs of the closed magnetic circuit magnetic core. Since the thickness of the peripheral terminals does not affect the window height of the closed magnetic circuit core, there is no dead space in the window height direction, the space factor can be improved, the window height of the closed magnetic circuit core can be reduced, and the choke coil with a lower height can be used. Can be realized, and the thickness of the inner peripheral terminal can be increased and the cross-sectional area can be increased, so that it is possible to cope with a large current.

[0008]

The invention according to claim 1 of the present invention is provided with a closed magnetic circuit core having a central magnetic leg, an outer magnetic leg, and a common magnetic leg, and a rectangular conductive wire or a rectangular conductor is attached to the central magnetic leg of the closed magnetic circuit core. Install an air-core coil in which a plate-shaped conductor consisting of a foil-shaped conductor is spirally wound, and at least the terminals connected to both ends of the plate-shaped conductor of this air-core coil are closed at least on the inner circumference of the air-core coil. It is drawn out to the outside through a notch or opening provided in at least one of the common magnetic cores of the magnetic path core, and the dead space in the window height direction of the magnetic core closed can be eliminated to improve the space factor and to close the magnetic magnetic path. The height of the magnetic core window can be reduced, and the thickness of the inner peripheral terminals can be increased to increase the cross-sectional area, making it possible to handle large currents.
This makes it possible to supply a choke coil corresponding to a large current having a lower height.

According to the second aspect of the present invention, the closed magnetic circuit magnetic core is a combination of EE type, EI type or TU type, which can be constituted by various combinations as described above, and the selection range of characteristics and assemblability can be set. Can be wide.

According to a third aspect of the present invention, in addition to the structure of the first aspect, a magnetic gap is provided in the central magnetic leg as a closed magnetic circuit magnetic core, and the choke can be performed without increasing the leakage flux outside the closed magnetic circuit magnetic core. The current superposition characteristic of the coil can be improved, and it becomes possible to supply a choke coil having a low leakage magnetic flux and a large current capacity.

According to a fourth aspect of the present invention, in addition to the constitution of the first aspect, the cross section of the central magnetic leg of the closed magnetic circuit magnetic core is circular, oval or elliptical, and the cross-sectional area of the central magnetic leg is As a result, the window width of the closed magnetic circuit magnetic core can be made larger, and the choke coil can be downsized.

According to a fifth aspect of the present invention, in addition to the structure of the first aspect, a portion of the common magnetic leg of the closed magnetic circuit core that corresponds to the terminal inside the common magnetic leg on the side where the notch or the opening is not provided. Even if the tip of the terminal connected to the plate-shaped conductor of the air-core coil goes out from the end face of the air-core coil, the contact between the terminal and the closed magnetic circuit magnetic core disappears, and the closed magnetic core is closed. Assembling defects of the magnetic leg can be eliminated, and it becomes possible to supply the choke coil with high workability and reliability.

According to a sixth aspect of the present invention, in addition to the structure of the first aspect, an EI type magnetic core is used as a closed magnetic circuit magnetic core, and a cutout or opening for drawing out a terminal inside the air-core coil is provided in the I type magnetic core. The position of the I-shaped magnetic core and the E-shaped magnetic core can be determined with respect to the air-core coil.
Since the central magnetic leg of the shaped magnetic core can prevent displacement of the insulating sheet, it is possible to supply a choke coil having excellent workability and characteristic stability.

According to a seventh aspect of the invention, in addition to the structure of the first aspect, the thickness of the common magnetic leg on the side provided with a notch or an opening for drawing out a terminal of the common magnetic leg as a closed magnetic circuit magnetic core is set to 1. In this case, the thickness of the common magnetic leg on the side not provided with the cutouts or openings is set to 0.65 to 0.9, and deterioration of the superposition characteristics of the closed magnetic circuit core due to the cutouts or openings of the common magnetic core is prevented. Can be prevented, excellent current superposition characteristics,
We can supply thin choke coils.

According to an eighth aspect of the present invention, in addition to the structure of the first aspect, the air-cored coil is formed by a self-bonding rectangular insulated wire, and an air-cored coil with high dimensional accuracy can be formed, thus improving workability. And automation is possible.

According to a ninth aspect of the present invention, in addition to the structure of the first aspect, the air-core coil is formed into a circular shape, an oval shape, or an elliptical shape according to the shape of the central magnetic leg of the closed magnetic circuit core.
We can supply choke coils with excellent space factor and winding workability.

According to a tenth aspect of the present invention, in addition to the structure of the first aspect, both ends of a plate-shaped conductor forming an air-core coil are bent so as to project inward and outward. It is possible to prevent the breakdown of the interlayer insulation due to the edges of both ends of the conductor wire, and it is possible to supply a choke coil with excellent reliability.

According to an eleventh aspect of the present invention, in addition to the structure of the first aspect, a spacer is interposed between the connecting portion of the terminals connected to both ends of the air-core coil and the plate-shaped conductor of the air-core coil. It is possible to prevent the interlayer insulation from being broken due to the burr at the terminal connection portion, and it is possible to supply the choke coil with excellent reliability.

According to a twelfth aspect of the present invention, in addition to the constitution of the eighth aspect, the air-core coil has a constitution in which the distance from the portion to which the terminals are connected to the end is made a little longer. It is possible to supply choke coils that are excellent in workability and can be automated because it is possible to prevent the collapse of the winding of the air-core coil by securely fixing and holding both ends in the long part from the part where the terminals are connected to the end. Become.

According to a thirteenth aspect of the present invention, in addition to the constitution of the first aspect, an insulating layer is interposed between the inner peripheral portion of the air-core coil and the central magnetic leg of the closed magnetic circuit core. , It is possible to prevent the air-core coil from being damaged when the air-core coil is incorporated in the closed magnetic circuit core, and it is possible to supply a choke coil having excellent workability and reliability.

According to a fourteenth aspect of the present invention, in addition to the structure of the first aspect, one of the closed magnetic circuit core and the insulator layer interposed between the inner peripheral portion of the air-core coil and the central magnetic leg of the closed magnetic circuit magnetic core. This is a structure in which an insulating layer that fits into the notch or opening of the common magnetic leg is integrally provided, and the positions of the air-core coil and the closed magnetic circuit magnetic core can be determined, and variations in characteristics can be reduced and the air-core coil can be reduced. It is possible to supply the choke coil that can be separated from the closed magnetic circuit core by the insulating layer, has a small number of parts, and has excellent characteristic stability, workability, and reliability.

According to a fifteenth aspect of the present invention, in addition to the structure of the thirteenth aspect, an insulating layer interposed between the inner peripheral portion of the air-core coil and the central magnetic leg of the closed magnetic circuit magnetic core is fitted to the central magnetic leg. Since it has a cylindrical shape, the clearance between the air-core coil and the central magnetic leg of the closed magnetic circuit core can be made small, and it becomes possible to supply a choke coil having an excellent space factor and reliability.

According to a sixteenth aspect of the present invention, in addition to the structure of the fourteenth aspect, one of the closed magnetic circuit core and the insulating layer interposed between the inner peripheral portion of the air-core coil and the central magnetic leg of the closed magnetic circuit magnetic core. Insulating layers that fit in the notches of the common magnetic legs are integrated, and both insulating layers are configured as a terminal block that holds the terminals at both ends of the air-core coil. The position can be determined and a choke coil with excellent terminal accuracy can be supplied.

According to a seventeenth aspect of the present invention, in addition to the structure of the sixteenth aspect, a wall piece for holding the outer peripheral surface of the air-core coil is provided on the outer end portion of the terminal block by the insulator layer on the inner peripheral portion of the air-core coil. Therefore, it is possible to supply a choke coil that prevents the outer dimensions of the air-core coil and the positional change with respect to the terminal block, has less characteristic variations, and has excellent workability and reliability.

According to an eighteenth aspect of the present invention, in addition to the configuration of the seventeenth aspect, the wall piece for holding the outer peripheral surface of the air-core coil is provided with a taper, and the air-core coil is guided by the taper of the wall piece. And can be easily inserted into the terminal block.

According to a nineteenth aspect of the present invention, in addition to the structure of the sixteenth aspect, two terminals are insert-molded on the terminal block, and both terminals are drawn outward from the same direction. Positioning can be performed accurately, and air core coil insertion and terminal connection can be automated.

According to a twentieth aspect of the present invention, in addition to the structure of the seventeenth aspect, the bent portions at both ends of the air-core coil are engaged with the insulator layer and the wall piece at the inner peripheral portion of the air-core coil of the terminal block. The engagement of the inner core of the air core coil prevents displacement of the air core coil, and the engagement of the outer core prevents collapse of the air core coil incorporated in the terminal block, resulting in stable characteristics, workability, and reliability. It enables the supply of choke coils with excellent properties.

According to a twenty-first aspect of the present invention, in addition to the structure of the sixteenth aspect, the terminal block is provided with guide portions for terminals connected to both ends of the air-core coil. It is possible to determine the position of the terminal provided on the part, automation is possible, and it becomes possible to supply choke coils with excellent workability and reliability.

According to a twenty-second aspect of the present invention, in addition to the configuration of the sixteenth aspect, an outer frame is provided integrally with the terminal block, and a magnetic core having at least both outer magnetic legs is incorporated from below the outer frame. Therefore, the air-core coil can be incorporated in the magnetic core using the outer frame as a guide, and it is possible to supply the choke coil which can be automated and has excellent workability.

According to a twenty-third aspect of the present invention, in addition to the configuration of the twenty-second aspect, a part of the outer frame is provided with a guide portion for guiding the terminal connected to the outer peripheral portion of the air-core coil, and both terminals are provided on opposite sides. Since the air-core coil terminals are drawn out from both directions and can be held by the terminal block, it is possible to supply a choke coil having a small number of parts and excellent terminal accuracy and workability.

According to a twenty-fourth aspect of the present invention, in addition to the configuration of the twenty-second aspect, a holding portion for holding a magnetic core incorporated from above is provided inside the four corners of the outer frame.
The magnetic core incorporated from above can be positioned, automation is possible, and it becomes possible to supply choke coils with excellent workability and characteristic stability.

According to a twenty-fifth aspect of the present invention, in addition to the structure of the twenty-second aspect, the outer frame has a height to cover the outer side surfaces of both outer magnetic leg sides when the closed magnetic circuit magnetic core is incorporated. The outer surface of the magnetic core can be insulated, and can be insulated from other components when the circuit is mounted.

According to a twenty-sixth aspect of the present invention, in addition to the structure of the first aspect, a closed magnetic circuit core has a circular central magnetic leg, and an air-core coil incorporated in this closed magnetic circuit core has a shape of an inner peripheral portion thereof. Only the distance between the winding start part and the side surface of the central magnetic leg that faces the terminal connecting part is approximately twice or more the thickness of the plate-shaped conductor wire, and the other parts have an oval shape similar to the central magnetic leg. With this structure, there is no wasted space between the air core coil and the center magnetic leg, and the required space can be obtained between the terminal connection part of the winding start part and the center magnetic core, and the space factor is excellent. An air-core coil having a small outer shape can be formed, which enables a smaller choke coil having a smaller board mounting area.

According to a twenty-seventh aspect of the present invention, in addition to the configuration of the first aspect, a concave cutout portion into which the outer circumference of the air-core coil is fitted is provided on the inner surfaces of both outer magnetic legs of the closed magnetic circuit core.
The window width of the closed magnetic circuit magnetic core can be increased, an air-core coil having a larger outer shape can be used, and a choke coil with higher performance can be supplied.

Embodiments of the present invention will be specifically described below with reference to the drawings. (Embodiment 1) A first embodiment of the present invention will be described with reference to FIGS. 1 to 5, reference numeral 20 denotes an air-core coil, and this air-core coil 20 is configured by spirally winding a plate-shaped conductor 21 made of a rectangular conductor or a foil conductor. Specifically, the plate-shaped conductive wire 21 is wound in a spiral shape using a self-fusing flat rectangular insulated wire, heated to soften the self-fusing layer on the surface, and fused together to form the air-core coil 20. Is formed.

Plate-shaped terminals 22 and 23 are connected to both ends of the air-core coil 20, that is, the inner peripheral portion and the outer peripheral portion, and the terminals 22 and 23 project below the air-core coil 20. Has been withdrawn. The terminals 22 and 23 are incorporated in the terminal block 24. That is, the terminal block 24
Is made of an insulating material such as synthetic resin, and has an arc-shaped piece 25 that rises upward along the inner peripheral surface of the air-core coil 20 at a position corresponding to the connection portion of the terminal 22 on the inner peripheral surface of the air-core coil 20, The arc-shaped piece 25 is formed by a triangular piece 26 connected at the lower end of the arc-shaped piece 25. The arc-shaped piece 25 and the triangular piece 26 each function as an insulating layer.

The arc-shaped piece 25 of the terminal block 24 has a step portion 27 having a different thickness in the middle portion, and a triangular piece 26 corresponding to the step portion 27 is provided with a terminal on the inner peripheral portion of the air-core coil 20. 22 is provided with a terminal hole 28 through which the air-core coil 2 is inserted.
A terminal hole 29 is provided in a triangular piece 26 corresponding to the terminal 23 on the outer peripheral portion of 0. Further, the lower surface of the triangular piece 26 is provided with terminal grooves 30 and 31 as terminal guide portions connected to the terminal holes 28 and 29.
After the terminal block 24 is combined with the terminal block 24, the terminals 22 and 23 projecting from the lower surface of the terminal block 24 are bent and fitted into the terminal grooves 30 and 31, so that they are pulled out to the side from the end surface of the triangular piece 26 of the terminal block 24. ing.

A closed magnetic circuit magnetic core 32 is incorporated in a combination of the air-core coil 20 and the terminal block 24. The closed magnetic circuit magnetic core 32 is formed of an EE-shaped magnetic core 33 made of a ferrite sintered body, and includes a central magnetic leg 34, both outer magnetic legs 35, and a common magnetic leg 36. The common magnetic leg 36 has a triangular shape of the terminal block 24. A notch 37 having a size into which the shaped piece 26 is fitted is provided.

With the above structure, the air-core coil 20 is connected to the terminal block 24.
, The terminals 22 and 23 are connected to the terminal groove 30 of the terminal block 24,
31. E-shaped magnetic core 33 is assembled from above and below by bending so as to fit along 31, and the triangular piece 26 of the terminal block 24 is fitted in the notch 37 of one E-shaped magnetic core 33 to position it.
By coupling the shaped magnetic cores 33, a choke coil having the terminals 22 and 23 drawn out in the same direction as shown in FIG. 2 is constructed.

At this time, both outer magnetic legs 35 of the E-shaped magnetic core 33
By making the height of the central magnetic leg 34 smaller than the height of the central magnetic leg 34, a choke coil having a magnetic gap 38 in the central magnetic leg 34 can be obtained, without increasing the leakage magnetic flux to the outside of the closed magnetic circuit magnetic core 32. The current superposition characteristic as a choke coil can be improved.

With the above structure, the triangular piece 26 of the terminal block 24 and the terminals 22 and 23 are arranged or pulled out by utilizing the cutout portion 37 of the common magnetic leg 36 of the closed magnetic circuit magnetic core 32. Therefore, the common magnetic leg 3 of the closed magnetic circuit magnetic core 32
Only the air-core coil 20 can be interposed between 6
The dead space in the window height direction of the closed magnetic circuit magnetic core 32 can be eliminated, the space factor can be improved, and the thickness of the terminals 22 and 23 can be increased to increase the cross-sectional area.

In the above embodiment, the closed magnetic circuit magnetic core 32 is used.
Although the EE type magnetic core 33 is used as an example, an EI type magnetic core or a TU type magnetic core may be used, and the central magnetic leg 34 of the closed magnetic circuit magnetic core 32 may have an oval shape or an elliptical shape in addition to the illustrated circular cross section. It may be shaped. This is an air core coil 2
The characteristics may be improved by reducing the gap between the air-core coil 20 and the central magnetic leg 34 in accordance with the shape of the inner peripheral portion of the air-core coil 20 after molding.

(Embodiment 2) Next, a second embodiment of the present invention will be described with reference to FIGS. The basic configuration is the same as that of the first embodiment, and only different points will be described. That is, the different point lies in the configuration of the terminal block 24, in which a wall piece 39 that rises upward is integrally provided on the outer end of the triangular piece 26, and a part of the inner and outer peripheral surfaces of the air-core coil 20 is provided on the terminal block 24. The arc-shaped piece 25 and the wall piece 39 are used for holding.

The terminals 22 and 23 are insert-molded in advance on the terminal block 24, and the ends of the inner and outer peripheral portions of the air-core coil 20 are insert-molded.
23 is connected and fixed later by a method such as welding or soldering.

With such a structure, it is possible to prevent changes in the outer dimensions of the air-core coil 20 and the position with respect to the terminal block 24, and to provide excellent reliability with little variation in characteristics.

As an improvement plan of the second embodiment, FIG.
It can also be configured as shown in FIG. That is,
The inner peripheral portion of the air-core coil 20 has an oval shape or an elliptical shape to improve the space factor of the air-core coil 20 in the closed magnetic circuit magnetic core 32. That is, if the inner peripheral portion of the air-core coil 20 is formed into a circular shape by the circular central magnetic leg 34 and the arcuate piece 25, a large amount of dead space is generated between them.

In order to make this dead space as small as possible, it is effective to make the shape of the inner peripheral portion of the air-core coil 20 oval or elliptical. This is the same as the wire jig 2 shown in FIG.
A structure in which an ellipse is formed by 2t, which is about twice the thickness t of 1, is used, and the spiral air-core coil 20 is configured and used by using this structure.

With this configuration, the air-core coil 20 having a high space factor and a small outer shape can be obtained, and the choke coil having a small size and a small mounting area can be obtained.

(Third Embodiment) Next, a third embodiment of the present invention will be described with reference to FIGS. 12 to 19, reference numeral 20 denotes an air-core coil, which has the same structure as that of the first embodiment and has terminals 22 and 23 at both ends.
Are connected so as to project downward.

On the other hand, the terminal block 24 incorporated in the air-core coil 20 has a cylindrical body 41 as an insulating layer between the air-core coil 20 and the central magnetic leg 34 of the closed magnetic circuit magnetic core 32, and a lower portion of the cylindrical body 41. It is constituted by a triangular piece 26 connected by parts. On the outer peripheral surface of the cylindrical body 41, there is provided a vertical groove 42 which serves as a guide portion into which the terminal 22 connected to the inner peripheral portion of the air-core coil 20 is fitted. The triangular piece 26 at the lower end of the vertical groove 42 is provided with a terminal. A hole 28 is provided.

Further, two wall pieces 39 are provided on the upper surface of the triangular piece 26 at a constant distance from the cylindrical body 41,
The tapered portion 4 is provided on the surface of the wall piece 39 facing the cylindrical body 41.
3 is provided so that the air-core coil 20 can be installed while being guided by the tapered portion 43. Further, the triangular piece 26 is provided with a terminal hole 29 through which the terminal 23 coupled to the outer peripheral portion of the air-core coil 20 is inserted, and the lower surface of the triangular piece 26 is connected to both terminal holes 28, 29. Terminal grooves 30 and 31 are provided as parts.

Further, as the closed magnetic circuit magnetic core 32, EI type magnetic cores 44 and 45 are used, and the E type magnetic core 44 has a central magnetic leg 34,
It is composed of both outer magnetic legs 35 and a common magnetic leg 36, and the common magnetic leg 36 is provided with a notch 37 having a size into which the triangular piece 26 of the terminal block 24 is fitted. On the other hand, the I-shaped magnetic core 45 has a substantially rectangular plate shape, and a cutout 46 is provided on a side corresponding to the cutout portion 37 of the E-shaped magnetic core 44.
A concave portion 47 is provided inside thereof. The notch 46 is provided on the terminal 23 connected to the outer peripheral portion of the air-core coil 20.
This is for the relief when the protrusions are upward, and the recess 47
Is for relief when the terminal 22 connected to the inner peripheral portion of the air-core coil 20 is connected so as to project upward.

As shown in FIG. 15, the I-shaped magnetic core 45 is not provided with the concave portion 47 and the terminal 22 is provided with the air-core coil 2.
When it projects above 0, the upper end of the terminal 22 comes into contact with the lower surface of the I-shaped magnetic core 45 and cannot be combined with the E-shaped magnetic core 44. However, by providing the concave portion 47 as shown in FIG. E-shaped magnetic core 44 with the upper end of 22 inserted
However, the I-shaped magnetic core 45 can be closely combined. The notch 46 of the I-shaped magnetic core 45 also exhibits the same effect when the terminal 23 projects upward.

With this structure, the air-core coil 20 having the terminals 22 and 23 connected thereto is attached to the terminal block 24 shown in FIG.
The tapered portions 43 of 9 are combined to insert the terminals 22 and 23 into the terminal holes 28 and 29, and the terminals 22 and 23 protruding from the lower surface of the terminal block 24 are bent to form a triangular piece 2 of the terminal block 24.
Inserted in the terminal grooves 30 and 31 on the lower surface of 6, and the triangular piece 2
6 is drawn out side by side, the E-shaped magnetic core 44 is combined therewith, and the I-shaped magnetic core 45 is arranged and fixed on the E-shaped magnetic core 44 to fix the magnetic gap between the end face of the central magnetic leg 34 and the I-shaped magnetic core 45. The choke coil shown in FIGS.

The terminal block 24 has been described as being formed by integrally molding the cylindrical body 41 and the triangular piece 26 with a resin. However, the terminal block 24 is formed as a separate body and mechanically coupled, or an adhesive is used to The configuration may be such that they are connected by.

(Fourth Embodiment) Next, a fourth embodiment of the present invention will be described with reference to FIGS. FIG.
0 to 22, the configurations of the air-core coil 20 and the terminal block 24 are the same as those of the third embodiment described above, and the closed magnetic circuit magnetic core 3
Only the configuration of 2 is changed. That is, the I-shaped magnetic core 45 is provided with the notch 37, the E-shaped magnetic core 44 is provided with the notch 46 on one side, and the recess 47 is provided therein. According to this configuration, the I-shaped magnetic core 45 is provided with the air-core coil 20. Embedded,
The triangular piece 26 of the terminal block 24, which is formed by bending and connecting the terminals 22 and 23, is positioned and combined with the notch 37, and the E-shaped magnetic core 44 is attached to the cylindrical body 41 of the terminal block 24 and the central magnetic leg 34. The choke coil shown in FIGS. 21 and 22 can be constructed by fitting and positioning while assembling.

This configuration is advantageous in terms of assembling because the I-shaped magnetic core 45 can be automatically positioned by the terminal block 24.

(Fifth Embodiment) Next, a fifth embodiment of the present invention will be described with reference to FIG. The basic configuration is the same as that of the fourth embodiment, and the different point is that the TU-shaped magnetic cores 48 and 49 are used to form the closed magnetic circuit magnetic core 32. That is, the T-shaped magnetic core 48 including the central magnetic leg 34 and the common magnetic leg 36, the both outer magnetic legs 35, and the common magnetic leg 36.
And a U-shaped magnetic core 49 composed of a U-shaped magnetic core 49, and a common magnetic leg 36 of the T-shaped magnetic core 48 is provided with a cutout portion 37 into which the triangular piece 26 of the terminal block 24 is fitted. With the configuration in which the notch 46 and the recess 47 are provided, the same effect as that of the fourth embodiment can be obtained.

(Sixth Embodiment) Next, a sixth embodiment of the present invention will be described with reference to FIGS. First, the air-core coil 20 will be described. The air-core coil 20 is a plate-shaped conductor 21 made of a self-bonding rectangular insulated wire.
However, it is designed to maintain its shape by self-bonding by heating by winding in a spiral shape, but the ends of the winding start and the winding end are peeled off by external force and swirled. In some cases, the condition cannot be maintained.

Therefore, an extension portion 50 is provided to extend the portion where the terminals 22 and 23 are connected to each other without making it the start end or the end, and the self-bonding property when heated is improved to prevent the spiral collapse. is there.

Moreover, the end portion is provided with a bent portion 51 projecting in the radial direction, that is, the inner peripheral portion is inward and the outer peripheral portion is protruded outward.

Further, the terminal block 24 is constructed such that the outer frame 52 is provided integrally with the triangular piece 26, the wall pieces 39 are provided near the four corners of the outer frame 52, and the outer magnetic leg 35 of the closed magnetic circuit magnetic core 32 is provided. The portion of the outer frame 52 corresponding to is designed to have the same height as the height of the closed magnetic circuit magnetic core 32 to protect the closed magnetic circuit magnetic core 32. Further, the triangular piece 2 of the outer frame 52
6, the terminal 2 on the outer peripheral side of the air-core coil 20
A terminal hole 29 for inserting 3 is provided.

Further, the cylindrical body 41 of the terminal block 24 has an uneven thickness structure in which the portion corresponding to the terminal 22 on the inner peripheral side of the air-core coil 20 has a thick wall thickness, and the terminal 2 is attached to this thick wall portion.
A vertical groove 42 for inserting and guiding 2 is provided, and an engaging groove 53 for engaging the bent portion 51 at the end portion of the inner peripheral portion of the air-core coil 20 is provided at a position slightly apart. A terminal hole 28 is provided in the triangular piece 26 corresponding to the lower end of the vertical groove 42, a terminal groove 30 connected to the terminal hole 28 is provided in the lower surface of the triangular piece 26, and the outer frame 52 is provided.
A terminal groove 31 is also provided on the lower surface of the portion where the terminal hole 29 is provided.

That is, in the terminal block 24 having this structure, the terminals 22 and 23 are drawn out in opposite directions, that is, in directions different by 180 degrees, so that the terminals 22 and 23 are effective as a choke coil for surface mounting. .

As the closed magnetic circuit magnetic core 32, an EI type magnetic core 44,
45, a concave cutout portion 54 is provided as a guide portion along the outer shape of the air-core coil 20 in the central portion on the inner side of the outer magnetic leg 35 of the E-shaped magnetic core 44, and a device for further miniaturization is added. Further, the I-shaped magnetic core 45 is provided with a recess 47 for escaping the terminal 22 on the inner peripheral side, and a notch 46 on the side opposite to the cutout 37 of the E-shaped magnetic core 44 to allow the terminal 23 on the outer peripheral side to escape. .

The lower surface of the I-shaped magnetic core 45 is provided with an insulating sheet 56 having a through hole 55 formed in the center thereof so as to fit with the central magnetic leg 34, thereby improving the insulation between the air-core coil 20 and the I-shaped magnetic core 45. I am trying to

The bent portion 51 at the end portion of the outer peripheral portion of the air-core coil 20 is one of the four wall pieces 39 provided integrally with the outer frame 52.
It is configured to be engaged with one end surface.

With such a structure, the air core coil 20 having an elliptical or elliptical inner periphery is provided on the terminal block 24 having the outer frame 52, the bent portion 51 of the air core coil 20 is engaged with the engaging groove 53 and the wall piece. The terminal hole 2 of the terminal block 24 is assembled by engaging with the end surface of 39.
The terminals 22 and 23 protruding through the lower surfaces of the terminal blocks 8 and 29 are bent and fitted into the terminal grooves 30 and 31, and the E-shaped magnetic core 44 having the cylindrical central magnetic leg 34 is incorporated from the lower surface of the terminal block 24. In the state of FIG. 25, the insulating sheet 56 is assembled, and then the I-shaped magnetic core 45 is assembled to form the choke coil shown in FIG.

The choke coil having this structure protects the closed magnetic circuit magnetic core 32 from an external impact and prevents the damage, and is excellent in safety. For example, the assemblability and the position fixing of the air-core coil 20 can be surely performed. It will have many advantages.

As the air-core coil 20 in the above description, as shown in FIGS. 29 (a) and 29 (b), one end of a plate-shaped conductor 21 made of a self-bonding rectangular insulated wire is bent at a right angle to form 1 One bent portion 51 is formed, the insulating layer is removed from a portion a little distance from both ends, and the terminals 22 and 23 are connected to the exposed conductor by caulking or welding.
In order to avoid the short circuit shown in FIG. 32 due to burrs generated at the time of connection, the spacers 57 as shown in FIG. 33 are attached to the surfaces opposite to the connecting portions of Nos. 2 and 23, which are spirally wound and then heated to each other. The structure as shown in FIG. 30 can be obtained by fusing and bending the outermost end so as to project to the outside to form a bent portion 51.

The bent portion 51 is provided at the end of the air-core coil 20.
When it is not necessary, the configuration shown in FIG. 31 can be adopted.

(Seventh Embodiment) Next, a seventh embodiment of the present invention will be described with reference to FIGS. The seventh embodiment is basically the same as the sixth embodiment in the basic configuration, and is different in that the terminal block 24 and the insulating sheet 5 are different.
In 6. That is, the terminal block 24 is the same in that it has the outer frame 52, the cylindrical body 41, and the triangular piece 26.
Inside the outer magnetic legs 35 of the E-shaped magnetic core 44, a support projection 58 also serving as a guide portion of the air-core coil 20 is provided in a square of an outer frame 52 having a size to be inserted, and a part of the support projection 58 is tapered. -Shaped notches 59 are provided, engaging pieces 60 cut and raised downward are provided at four corners of the insulating sheet 56, and the engaging pieces 60 are fitted into the tapered notches 59 to position the insulating sheet 56. .

No through hole 55 is provided in the center of the insulating sheet 56, and the central magnetic leg 34 of the E-shaped magnetic core 44 and the I-shaped magnetic core 4 are provided.
5 is formed by interposing the insulating sheet 56.

With the above structure, the air-core coil 20 is incorporated in the terminal block 24 as shown in FIG. 35, the terminals 22 and 23 are bent in the opposite directions and pulled out, and then the terminal block 24 is drawn as shown in FIG. The E-shaped magnetic core 44 is incorporated from the bottom surface of the
As shown in FIG.
It is fitted into the tapered notch 59 of the terminal while positioning it, and finally the I-shaped magnetic core 45 is attached to the terminal blocks 24 and E.
Assembled so as to ride on the outer magnetic leg 35 of the shaped magnetic core 44, as shown in FIG.
8 and the choke coil shown in FIG. 39.

The central magnetic leg 34 of the E-shaped magnetic core 44 constituting the closed magnetic circuit magnetic core 32 has an oval or elliptical shape as shown in FIG. 40, and the air-core coil 20 has an oval or elliptical spiral shape. As described above, the positioning may be performed by the shape by the combination of both, and the space factor may be improved.

In the case where the closed magnetic circuit magnetic core 32 is configured such that one common magnetic leg 36 is provided with the notch 37 and the other common magnetic leg 36 is not provided with the notch 37, the notch 37 is formed.
When the thickness of the common magnetic leg 36 provided with is set to 1, the notch 3
Even if the thickness of the common magnetic leg 36 without 7 is reduced to 0.65 to 0.9, the characteristics of the choke coil are not changed, and the height of the choke coil can be reduced accordingly.

In each of the above embodiments, the notch 37 is formed in at least one common magnetic leg 36 of the closed magnetic circuit core 32.
However, instead of the cutout portion 37, an opening is provided at a portion corresponding to the terminals 22 and 23 connected to the inner and outer peripheral portions of the air-core coil 20, and instead of the triangular piece 26 as the terminal block 24. It is also possible to form a plate piece that fits into this opening.

[0078]

Since the choke coil of the present invention is constructed as described above, substantially only the air-core coil can be arranged in the window portion between the common magnetic legs of the closed magnetic circuit core, which is thin. In addition, it is possible to use a terminal having a large thickness as the lead-out terminal of the air-core coil, and it is possible to cope with a large current.

[Brief description of drawings]

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

FIG. 2 is a perspective view of a finished product of the choke coil.

FIG. 3 is a sectional view of the same.

FIG. 4 is a top view of the same magnetic core from which the magnetic core is removed.

FIG. 5 is a perspective view of a terminal block used for the choke coil.

FIG. 6 is a perspective view of a choke coil according to a second embodiment of the present invention.

FIG. 7 is a sectional view of the same.

FIG. 8 is a top view of the state in which the same magnetic core is removed.

FIG. 9 is a perspective view of a terminal block used for the choke coil.

FIG. 10 is a top view of the choke coil with one magnetic core removed.

FIG. 11 is an explanatory view for manufacturing the air-core coil.

FIG. 12 is an exploded perspective view of a choke coil according to a third embodiment of this invention.

FIG. 13 is a perspective view of the same.

FIG. 14 is a sectional view of the same.

FIG. 15 is a cross-sectional view showing an inconvenience when the I-shaped magnetic core of the same configuration has no recess.

FIG. 16 is a cross-sectional view showing a state where a recess is provided in the same I-shaped magnetic core.

FIG. 17 is a top view of the same I-shaped magnetic core with the core removed.

FIG. 18 is a perspective view of the terminal block.

FIG. 19 is a perspective view showing a state where an air-core coil is combined with the terminal block.

FIG. 20 is an exploded perspective view of a choke coil according to a fourth embodiment of this invention.

FIG. 21 is a perspective view of the finished product.

FIG. 22 is a sectional view of the same.

FIG. 23 is an exploded perspective view of a choke coil according to a fifth embodiment of the present invention.

FIG. 24 is an exploded perspective view of a choke coil according to a sixth embodiment of the invention.

FIG. 25 is a perspective view showing a state where the air-core coil and the terminal block are combined.

FIG. 26 is a perspective view showing a state in which the air-core coil, the terminal block and the E-shaped magnetic core are combined.

FIG. 27 is a top view of the same.

FIG. 28 is a sectional view of the finished product.

29A is a top view of the air-core coil before winding, and FIG. 29B is a front view of the same.

FIG. 30 is a top view of the air-core coil.

FIG. 31 is a top view of another example of the air-core coil.

FIG. 32 is an explanatory view showing the inconvenience of the terminal connecting portion of the air-core coil.

FIG. 33 is an explanatory view showing a state in which a spacer is interposed at a terminal connecting portion of the air-core coil.

FIG. 34 is an exploded perspective view showing a choke coil according to a seventh embodiment of the present invention.

FIG. 35 is a perspective view showing a state where the air-core coil and the terminal block are combined.

FIG. 36 is a perspective view showing a state in which the air-core coil, the terminal block and the E-shaped magnetic core are combined.

FIG. 37 is a perspective view showing a state where an insulating sheet is incorporated in the same.

FIG. 38 is a perspective view of the finished product.

FIG. 39 is a sectional view of the same.

FIG. 40 is a top view showing a modified example of the E-shaped magnetic core.

FIG. 41 is a top view showing a state in which an air-core coil is combined with the magnetic core.

FIG. 42 is an exploded perspective view showing a conventional choke coil.

FIG. 43 is a perspective view before assembling the magnetic cores of the same side.

FIG. 44 is a perspective view of the finished product.

FIG. 45 is a sectional view of the same.

FIG. 46 is a top view showing a state where the magnetic cores on the same side are removed.

[Explanation of symbols]

 20 air core coil 21 plate-like conductor 22, 23 terminal 24 terminal block 25 arcuate piece 26 triangular piece 27 step 28, 29 terminal hole 30, 31 terminal groove 32 closed magnetic core 33 EE magnetic core 34 central magnetic leg 35 outer magnetic Leg 36 Common magnetic leg 37 Notch 38 Magnetic gap 39 Wall piece 40 Winding jig 41 Cylindrical body 42 Vertical groove 43 Tapered portion 44 E-shaped magnetic core 45 I-shaped magnetic core 46 Notched 47 Recessed 48 T-shaped magnetic core 49 U-shaped magnetic core 50 Extended portion 51 Bent portion 52 Outer frame 53 Engagement groove 54 Recessed portion 55 Through hole 56 Insulation sheet 57 Spacer 58 Support protrusion 59 Tapered notch 60 Engagement piece

Claims (27)

[Claims] 1. A closed magnetic circuit core having a central magnetic leg, an outer magnetic leg, and a common magnetic leg, wherein a plate-shaped conductor made of a rectangular conductor or a foil conductor is spirally wound on the central magnetic leg of the closed magnetic circuit core. The air core coil is attached, and at least one of the terminals connected to both ends of the plate-shaped conductor of the air core coil is provided on the inner circumference of the air core coil on at least one of the common magnetic legs of the closed magnetic circuit cores. A choke coil that is drawn out through a notch or opening. 2. The choke coil according to claim 1, wherein the closed magnetic circuit magnetic core is constituted by a combination of an EE type, an EI type and a TU type. 3. The choke coil according to claim 1, wherein a magnetic gap is provided in a center magnetic leg as a closed magnetic circuit core. 4. The choke coil according to claim 1, wherein the cross section of the central magnetic leg of the closed magnetic circuit core is circular, oval or elliptical. 5. A recess, a notch or a hole is provided in a portion corresponding to a terminal inside the common magnetic leg on the side of the common magnetic leg of the closed magnetic circuit core where the notch or opening is not provided. The listed choke coil. 6. An EI type magnetic core is used as a closed magnetic circuit core,
The choke coil according to claim 1, wherein a notch or an opening for leading out a terminal inside the air-core coil is provided in the I-shaped magnetic core. 7. A common magnetic leg on the side where a cutout or an opening is not provided when the thickness of the common magnetic leg on the side provided with a cutout or an opening for drawing out a terminal among the common magnetic legs as a closed magnetic circuit magnetic core is 1. The choke coil according to claim 1, wherein the thickness of the choke coil is 0.65 to 0.9. 8. The choke coil according to claim 1, wherein the air-core coil is composed of a self-bonding rectangular insulated wire. 9. The choke coil according to claim 1, wherein the air-core coil has a circular shape, an oval shape, or an elliptical shape that matches the shape of the central magnetic leg of the closed magnetic circuit magnetic core. 10. The choke coil according to claim 1, wherein both ends of a plate-shaped conductor forming the air-core coil are bent so as to project inward and outward. 11. The choke coil according to claim 1, wherein a spacer is interposed between the connecting portion of the terminals connected to both ends of the air-core coil and the plate-shaped conductor of the air-core coil. 12. The choke coil according to claim 8, wherein the distance from the portion to which the terminals are connected to the end is slightly increased as an air-core coil. 13. The choke coil according to claim 1, wherein an insulator layer is interposed between the inner peripheral portion of the air-core coil and the central magnetic leg of the closed magnetic circuit core. 14. An insulating layer interposed between an inner peripheral portion of an air-core coil and a central magnetic leg of a closed magnetic circuit core, and an insulating layer fitted in a notch or an opening of one common magnetic leg of the closed magnetic circuit core. The choke coil according to claim 1, wherein the choke coil is integrally provided. 15. The choke coil according to claim 13, wherein the insulator layer interposed between the inner peripheral portion of the air-core coil and the central magnetic leg of the closed magnetic circuit magnetic core has a cylindrical shape fitted in the central magnetic leg. 16. An insulating layer interposed between an inner peripheral portion of the air-core coil and a central magnetic leg of the closed magnetic circuit core, and an insulating layer fitted in a notch of one common magnetic leg of the closed magnetic circuit core. The choke coil according to claim 14, wherein the choke coil is integrated, and the two insulating layers are used as a terminal block that holds terminals at both ends of the air-core coil. 17. The choke coil according to claim 16, wherein a wall piece for holding the outer peripheral surface of the air-core coil is provided on the outer end of the terminal block by the insulator layer on the inner periphery of the air-core coil. 18. The choke coil according to claim 17, wherein the wall piece that holds the outer peripheral surface of the air-core coil is provided with a taper. 19. The choke coil according to claim 16, wherein two terminals are insert-molded on the terminal block, and both terminals are drawn outward from the same direction. 20. The choke coil according to claim 17, wherein the bent portions at both ends of the air-core coil are engaged with the insulator layer and the wall piece at the inner periphery of the air-core coil of the terminal block. 21. The choke coil according to claim 16, wherein the terminal block is provided with guide portions for terminals connected to both ends of the air-core coil. 22. The choke coil according to claim 16, wherein an outer frame is provided integrally with the terminal block, and a magnetic core having at least both outer magnetic legs is incorporated from below the outer frame. 23. The choke coil according to claim 22, wherein a guide portion for guiding a terminal connected to an outer peripheral portion of the air-core coil is provided in a part of the outer frame, and both terminals are drawn out to opposite sides. 24. The choke coil according to claim 22, wherein holding portions for holding a magnetic core incorporated from above are provided inside four corners of the outer frame. 25. The choke coil according to claim 22, wherein when the outer frame incorporates a closed magnetic circuit core, the outer frame has a height to cover the outer surfaces of the outer magnetic legs. 26. A magnetic core having a circular central magnetic leg as a closed magnetic circuit magnetic core, and as a coreless coil incorporated in this closed magnetic circuit magnetic core, a central magnetic leg having a shape of an inner peripheral portion facing a winding start portion and a terminal connecting portion. Only the distance from the side of the plate-shaped conductor is about 2
The choke coil according to claim 1, wherein the choke coil has a length equal to or more than double, and the other portion has an elliptical shape similar to the center magnetic leg. 27. The choke coil according to claim 1, wherein recessed portions for fitting the outer circumference of the air-core coil are provided on the inner surfaces of both outer magnetic legs of the closed magnetic circuit magnetic core.