JPH09219326A - Sheet transformer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the number of parts and decrease the number of working steps in a sheet transformer used for various electronic apparatuses. SOLUTION: A spiral coil 12 made of punched thin conductor plates is arranged on an insulative film 13a having a magnetic core leg inserting hole 14a, a projection part 18a integral with the insulative film 13a is bent on the coil 12, a lead-out part 15 is bent so as to lead it out outward of the coil 12 on the projection part 18a, and an insulative film 13b is disposed thereon to form a sheet coil. At this time, the projection part 18a integral with the insulative film 13a is provided, whereby an attempt is made to reduce the number of parts and decrease the number of working steps.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet transformer used for various video equipment, industrial equipment, audio equipment and the like.

[0002]

2. Description of the Related Art In recent years, the frequency of sheet transformers has been increasing with the aim of making them smaller and thinner, and a spiral coil in which a thin conductor plate is punched out is used to suppress the increase in high frequency resistance, and We are trying to reduce the temperature rise.

A sheet coil used in a conventional sheet transformer will be described below with reference to FIGS. According to the figure, 1 is a spiral coil having a punched-out conductor plate, 2 is a lead-out portion at the inner peripheral end, 3 is a coil insulating tape, and 4 is an insulating film.

Explaining the sheet coil constructed as described above, first, as shown in FIG. 7B, the spiral coil 1 in which a thin conductor plate is punched out as shown in FIG. Insulation tape 3 is formed by bending the part 2 and insulating the bent part from the spiral coil 1.
Then, the insulating films 4 were arranged on both surfaces of the spiral coil 1 to form a sheet coil as shown in FIG.

Although not shown, the sheet transformer is formed by laminating a plurality of sheet coils having different numbers of turns.

[0006]

However, in the above-mentioned conventional sheet coil structure, the innermost peripheral end portion of the spiral coil 1 having a thin conductor plate punched out is always insulated between the portion 2 and the coil portion which are drawn out to the outside of the coil. Insulation must be secured by attaching the tape 3, and it becomes necessary to increase the size of the insulation tape 3 in order to prevent misalignment and poor insulation as shown in FIG. It takes a lot of work to perform well.

An object of the present invention is to provide a sheet transformer at low cost by using a coil having a stable insulation structure.

[0008]

In order to solve this problem, in the sheet transformer of the present invention, a projecting portion is integrally formed at one end of an insulating film for sandwiching a spiral coil, and the projecting portion is bent. The spiral coil is sandwiched between the drawing portion and the coil surface.

With the above structure, the drawn-out portion of the spiral coil and the protruding portion for insulating the spiral coil are bent while being connected to the insulating film, so that the positional deviation does not occur, and since they are integrally formed, the coil is insulated. The tape will be deleted and the work man-hours will be reduced.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention according to claim 1 of the present invention has a spiral coil formed by punching out a thin conductor plate into a spiral shape, and a hole for inserting a magnetic leg and sandwiching the spiral coil. Two insulating films arranged as described above, a lead-out portion of the inner peripheral end of the spiral coil that is bent and protrudes outward of the spiral coil, and at least one end of the two insulating films is integrally formed. A projecting portion which is provided and bent inward and is arranged between the spiral coil and the lead-out portion; and a magnetic core which is incorporated by inserting a magnetic leg into the magnetic leg insertion hole from the outside of the two insulating films. The coil coil does not require a separate coil insulation tape to secure the insulation between the spiral coil and the extraction part of this spiral coil. Reduce the number of parts by the Irumu and integrated, in which attained a reduction of working steps.

According to a second aspect of the present invention, in addition to the structure of the first aspect, the insulating film is integrally formed so that one side different from the side provided with the protruding portion at the end is continuous with the corresponding side on the other side. Since the spiral coil is clamped and clamped to sandwich the spiral coil, the number of insulating films can be reduced to further reduce the work man-hours.

According to a third aspect of the present invention, in addition to the structure of the second aspect, the side opposite to the side having the protruding portion of the same insulating film is integrated with the other side and the lead-out portion of the spiral coil is formed. In the drawing direction, the width of the insulating film integrated and folded back is substantially the same as the width of the main body of the spiral coil, so that the position of the spiral coil in the drawing direction of the drawing portion of the spiral coil can be easily regulated.

According to a fourth aspect of the present invention, there is provided a spiral coil formed by punching out a thin conductor plate in a spiral shape, and two spiral coils each having a hole for inserting a magnetic leg and arranged so as to sandwich the spiral coil. An insulating film, a lead-out portion of the inner peripheral end of the spiral coil that is bent and protrudes outward of the spiral coil, and corresponds to the lead-out portion in at least one of the holes for inserting the magnetic legs, and from this lead-out portion. A protrusion provided with a small protrusion amount and bent outward together with the lead-out portion and arranged between the spiral coil and the lead-out portion, and a magnetic leg from the outside of the two insulating films to the magnetic leg insertion hole. Since it is configured with a magnetic core that is inserted and incorporated, the protrusion is provided in the hole for inserting the magnetic leg of the insulating film, and the originally discarded part is used. It is intended to improve the material yield of the insulating film.

An embodiment of the seat transformer of the present invention will be described below with reference to FIGS.

(First Embodiment) FIG. 1 is a perspective view of a seat transformer, and FIG. 2 is an exploded perspective view of a seat coil which is a main part.

As shown in FIG. 1, 11 is a magnetic core made of EE type or EI type ferrite, 12 is a spiral coil made by punching a thin conductor plate, 13a and 13b are insulating films, and 14a and 14b are magnetic legs. , 15 is a lead-out portion for external connection of the inner peripheral end of the spiral coil 12,
Reference numeral 16 is a coil support, 17 is a guide wall inside the coil support 16, and 18a is a protrusion integral with the insulating film 13a.

Next, the sheet coil portion will be described in detail. The insulating film 1 having a hole 14a for inserting a magnetic leg.
Spiral coil 1 with a thin conductor plate stamped on 3a
2 is arranged, the protruding portion 18a of the insulating film 13a is bent on the spiral coil 12, and the lead-out portion 15 is bent on the protruding portion 18a so as to be drawn to the outside of the spiral coil 12. Further, there is a hole 14 for inserting a magnetic leg.
The insulating film 13b having b is arranged so as to sandwich the spiral coil 12 with the insulating film 13a to complete the sheet coil. Next, as shown in FIG. 1, the coil support 1
The sheet coils are sequentially stacked and inserted into the guide wall 17 of No. 6 so that the holes 14a and 14b for inserting the magnetic legs correspond to each other.
To complete a thin sheet transformer.

The number of turns of each spiral coil 12 of the laminated sheet coils used for the sheet transformer is generally different.

Although the holes 14a, 14b for inserting the magnetic legs have been described as being provided in advance in the respective insulating films 13a, 13b, they may be provided in the state of sheet coil.
It may be provided after stacking the sheet coils, and both are within the technical scope of the present invention.

With the above structure, since the protruding portion 18a for separating the lead-out portion 15 and the spiral coil 12 from each other at the intersecting position is integrally provided on the insulating film 13a, the positioning is easier and the number of parts is greater than that of the conventional insulating tape. It is also possible to reduce the work man-hours.

(Embodiment 2) FIG. 3 is a front view of an insulating film which is an essential part, and FIGS. 4A to 4D are front views of a sheet coil which explains an assembly procedure of an essential part of the sheet coil. It is a figure and Drawing 5 is the same side sectional view.

Since the other parts are the same as those in the first embodiment, the description thereof will be omitted. The difference from the first embodiment will be that the insulating film on both sides for enclosing the spiral coil 12 as shown in FIG. 13d is integrally formed by connecting the outer ends of the opposite sides that are the folded-back portions where the protruding portions 18b are not formed, and the outer peripheral diameter of the lead-out portion 15 of the spiral coil 12 in the lead-out direction and the insulating film 13.
This is a point in which the dimension from the side having the protruding portion 18b of d to the folded surface of the insulating film 13d, which is the opposite side, is substantially the same.

Explaining the procedure for assembling the sheet coil, first, as shown in FIG. 4A, the spiral coil 12 is placed on the insulating film 13d. Next, as shown in FIG. 4 (b), the protruding portion 18b integral with the insulating film 13d is bent inward, and further the lead-out portion 15 is bent outward as shown in FIG. 4 (c). Finally, as shown in FIG. 4 (d). As described above, the folded portion of the upper insulating film is bent and wrapped from the upper portion of the spiral coil 12 to complete the sheet coil.

According to the above configuration, the spiral coil 1
Since the insulating films 13d on both sides of No. 2 are also integrated, no positional deviation occurs. Further, since the dimension of the insulating film 13d up to the folded portion and the outer diameter of the spiral coil 12 in the pull-out direction are substantially the same, the spiral coil 12 is formed by the folded portion and the bent protruding portion 18d.
The position is regulated so that there is no deviation and the peculiar effect that the insulation distance between the spiral coil 12 and the magnetic core 11 is kept stable even in the inner surface portion of the spiral coil 12 incorporating the central magnetic leg can be obtained.

If it is not necessary to regulate the position of the spiral coil 12 by the folded-back portion and the bent protruding portion 18d, the outer diameter of the lead-out portion 15 in the pulling-out direction, the side having the protruding portion 18b, and the folded-back portion. It is not necessary to make the distances approximately the same size, and the insulating films 13 forming the both surfaces
For the integration of d, the folding film may be provided on the side different from the projecting portion 18b, and the insulating film may be obtained by continuously integrating with the corresponding other side to form both surfaces.

In the above case, the function of restricting the position of the spiral coil 12 is impaired, but since three parts can be made into one part as compared with the conventional one, the number of parts and the work man-hour are reduced. Since there is a degree of freedom in the direction in which both surfaces of the insulating film 13d are integrated, the insulating film 13d has a feature that it is possible to make an advantageous selection for material yield.

(Third Embodiment) FIG. 6 is a perspective view of a sheet coil which is an essential part. The difference from the first embodiment is that the sheet coil is slightly protruded from a lead-out portion 15 so as to protrude into a hole 14d for inserting a magnetic leg. The shortened protruding portion 18c is provided in advance, and when the lead-out portion 15 is bent, the lead-out portion 15 is also bent outward at the same time to separate the spiral coil 12 from the lead-out portion 15. By making the protrusion 18c slightly shorter than the lead-out portion 15, a part of the lead-out portion 15 is exposed and becomes a terminal for connection with the other.

With the above construction, since the protrusion 18c is provided in the hole 14d for inserting the magnetic leg, it is possible to improve the material yield when the insulating film 13c is manufactured.

Further, in the above structure, the insulating film 1
Although the protruding portion 18c is provided on 3c, a similar protruding portion may be provided on the opposite insulating film on the opposite side, and by providing it on both sides, the bending direction of the drawer portion 15 can be appropriately selected.

[0030]

As described above, in the sheet transformer of the present invention, the protruding portion is integrally formed at one end of the insulating film that holds the spiral coil, and the protruding portion is bent to form the lead-out portion of the spiral coil. Since it is sandwiched between the coil surfaces, the extraction part of the spiral coil and the protruding part that insulates the spiral coil are bent while being connected to the insulating film, so there is no misalignment and they are formed integrally. Therefore, the insulating tape of the coil is deleted and the work man-hours are reduced.

[Brief description of drawings]

FIG. 1 is a perspective view of an embodiment of a seat transformer of the present invention.

FIG. 2 is an exploded perspective view of a sheet coil which is a main part of the same.

FIG. 3 is a front view of an insulating film, which is a main part of another embodiment.

FIG. 4 is an explanatory view for explaining an assembling procedure of the sheet coil which is the main part.

FIG. 5 is a side sectional view of the same.

FIG. 6 is a perspective view of a sheet coil which is a main part of the other embodiment.

FIG. 7 is an explanatory view for explaining a procedure for assembling a sheet coil which is a main part of a conventional sheet transformer.

FIG. 8 is a perspective view for explaining the same problem.

[Explanation of symbols]

 11 Magnetic Core 12 Spiral Coil 13a, 13b, 13c, 13d Insulating Film 14a, 14b Hole for Inserting Magnetic Leg 15 Drawout 16 Coil Support 17 Guide Walls 18a, 18b, 18c Projection

Claims (4)

[Claims] 1. A spiral coil formed by punching out a thin conductor plate to form a spiral shape, and two insulating films having holes for inserting magnetic legs and arranged so as to sandwich the spiral coil. A lead-out portion at the inner peripheral end of the spiral coil projecting outward of the spiral coil and at least one of the end portions of the two insulating films are integrally provided and bent inward to form the spiral coil and the lead-out portion. A sheet transformer including a protrusion arranged between the two insulating films, and a magnetic core inserted by incorporating a magnetic leg into the hole for inserting the magnetic leg from the outside of the two insulating films. 2. The sheet according to claim 1, wherein the insulating film is integrated so as to be continuous with the corresponding side of the other side at one side different from the side provided with the protruding portion at the end and sandwiching the spiral coil. Trance. 3. The same insulating film is integrated with the other side at the side opposite to the side having the protruding portion, and is integrated with the width of the main body of the spiral coil in the withdrawing direction of the withdrawing portion of the spiral coil and folded back. The sheet transformer according to claim 2, wherein the insulating films have substantially the same width. 4. A spiral coil formed by punching out a thin conductor plate in a spiral shape, and two insulating films having holes for inserting magnetic legs and arranged so as to sandwich the spiral coil. The lead-out portion at the inner peripheral end of the spiral coil projecting outward of the spiral coil and at least one of the holes for inserting the magnetic legs are provided so as to correspond to the lead-out portion and have a projecting amount smaller than that of the lead-out portion. A projecting part which is bent outward together with the drawing part and is arranged between the spiral coil and the drawing part, and a magnetic core incorporated by inserting a magnetic leg into the hole for inserting the magnetic core from the outside of the two insulating films. A sheet transformer composed of and.