JPH10208944A - Inductor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase the space factor of a coil, to reduce the number of parts used in the coil, and to eliminate the heat generation by a coil due to a copper loss by molding the coil so that both end sections of the coil may be drawn out and forming a molded coil by bending both end sections along the molded surface, and then, burying an E-shaped magnetic core in the molded coil. SOLUTION: A coil 1 is composed of a flat copper wire and vertically wound around a magnetic core 2 with the cylindrical magnetic leg 12 of the core 2 at the center. Then a molded coil 3 is obtained by molding the coil 1 with an epoxy resin, etc., so that both end sections of the coil 1 may be drawn out and terminals are formed by bending the drawn-out parts of the coil 1 along the molded surface 4. In addition, an inductor is obtained by butting two magnetic cores 2 against the molded coil 3. The magnetic core 2 is made of a soft magnetic ferrite and has an E-shaped cross section, magnetic legs 13 at both ends, a cylindrical magnetic core 12 at the center, and structures which can house the coil 1 in the recessed sections between the magnetic leg 12 and magnetic legs 13.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to various power supply devices,
The present invention relates to an inductor used for a video device, an audio device, an industrial device, a communication device, an information-related device, and the like, and particularly to an inductor in which a core is incorporated in a rectangular copper wire.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 4, a round copper wire 21 is attached to a toroidal type magnetic core 22 as shown in FIG.
And a structure in which an EE-type or EI-type magnetic core 33 is incorporated in a bobbin 34 having a terminal 35 as shown in FIG.

[0003] However, in the former case, there is a problem that it takes a long time to work because the winding is performed manually.
In addition, since the space factor of the coil is reduced by the round copper wire, there is a problem that the size of the inductor must be increased in order to obtain an inductor having a large current capacity.

[0004] In the latter case, there is a problem that the number of parts increases and the number of man-hours increases. In addition, since a terminal made of phosphor bronze or the like is used, there is a problem that a direct current resistance at the portion is increased and heat generation due to copper loss is increased.

[0005]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems and has a high space factor of the coil, a small number of parts,
An object of the present invention is to provide a small, inexpensive, and highly reliable inductor that does not generate heat due to copper loss.

[0006]

SUMMARY OF THE INVENTION The present invention provides a coil in which a rectangular copper wire is vertically wound, that is, a coil which is bent in the width direction and laminated with a wider surface is wound at both ends of the coil. Molded so that both ends are bent along the molded surface to form a molded coil, and the molded coil incorporates an E-shaped magnetic core having a columnar magnetic leg in the center. This is a characteristic inductor.

Further, the present invention is an inductor characterized in that an E-shaped magnetic core is incorporated in a coil in which a rectangular copper wire is vertically wound.

Further, the present invention is the above-mentioned inductor, wherein a coil is used in which at least two or more rectangular copper wires are arranged in parallel in the width direction and vertically wound.

As described above, when one rectangular copper wire is wound vertically, elongation deformation occurs outside the bent portion, and shrinkage deformation occurs inside the bent portion. If this is severe, the insulating coating may be damaged on the outside and inside of the bent portion of the rectangular copper wire. This problem can be solved by arranging a plurality of rectangular copper wires in parallel in the width direction and vertically winding them.

Further, according to the present invention, by using a rectangular copper wire, the space factor of the coil can be increased, and the size of the inductor can be reduced. Also, by molding the coil, insulation between the core and the coil can be ensured.
In addition, by using both ends drawn from the molded coil directly as terminals, it is not necessary to use a terminal block and a bobbin. Therefore, the number of components can be reduced, the manufacturing process can be simplified, and in addition, heat generation due to copper loss of the terminal can be eliminated.

[0011]

Embodiments of the present invention will be described below.

(Embodiment 1) FIG. 1 is an explanatory view showing a coil and a magnetic core used in an inductor according to an embodiment of the present invention. FIG. 1 (a) shows one magnetic core in the coil. FIG. 1B is a cross-sectional view illustrating a state in which two magnetic cores are incorporated in a coil.
FIG. 1C is a side view showing the magnetic core. When the coils are shown, the number of magnetic cores is also shown together with the number of coils so that the positional relationship with the magnetic cores can be easily understood. FIG. 1B is a cross-sectional view when the magnetic leg at the center of the magnetic core is cut.

FIGS. 2A and 2B are explanatory views showing a state in which a coil used for an inductor according to an embodiment of the present invention is molded with resin. FIG. 2A is a plan view, and FIG.
2 (c) is a bottom view, and FIG. 2 (d) is a perspective view.

In one embodiment of the present invention, the inductor
It is composed of magnetic cores and coils.

As shown in FIGS. 1 (a) and 1 (b),
The coil 1 is made of a rectangular copper wire, and is vertically wound around a columnar magnetic leg 12 of the magnetic core 2.

On the other hand, as shown in FIGS. 1 (b) and 1 (c), the magnetic core 2 is made of soft magnetic ferrite, has an E-shaped cross section, magnetic legs 13 at both ends, and a columnar shape at the center. Magnetic legs 12
And a structure in which the coil 1 can be housed in the concave portion between the magnetic legs 12 and 13, and two coils are used in abutting relation.

Using the magnetic core and the coil having such a structure, the inductor of the present invention is assembled as follows. First, as shown in FIG. 2, the coil 1 having the above-described structure is molded with an epoxy resin or the like so that both ends thereof are pulled out, and a molded coil 3 is obtained.
Next, the drawn portion is bent along the molded surface 4 to form a terminal. Furthermore, two of the above-mentioned magnetic cores are butted against the molded coil 3 to obtain the inductor of the present invention.

In the terminal 5, in the first embodiment, a groove is formed so that the surface of the terminal 5 formed by bending the end of the coil 1 and the molded surface 4 are flush with each other. A structure in which the ends of the coil are simply bent without forming a simple groove may be used.

(Embodiment 2) Next, an inductor according to another embodiment will be described. FIG. 3 is an explanatory view showing a coil and a magnetic core used in an inductor according to another embodiment of the present invention, and FIG. 3A is a plan view showing a state where one magnetic core is incorporated in the coil. , FIG. 3 (b)
It is sectional drawing which shows the state which integrated two magnetic cores in the coil.

As shown in FIG. 3, the coil 11 is formed by arranging and winding two narrow rectangular copper wires in parallel. That is, the coil of the above embodiment has a structure in which the center is divided into two in the longitudinal direction.

Using the coil 11, molding is performed in the same manner as described above, the end is bent, and a terminal is formed. Then, the magnetic core is butted to obtain an inductor of another embodiment.

(Embodiment 3) In this embodiment, an example of an inductor that is not molded will be described. Using two magnetic cores and coils similar to those of the first and second embodiments, FIG.
A magnetic core is butted and assembled into the coil so as to be in the state shown in FIG. 2B or FIG. Thereafter, the butted magnetic cores are fixed by using an insulating tape or a holder or the like, and a non-molded type inductor is obtained.

In the first to third embodiments, one and two rectangular copper wires have been described. However, in order to obtain inductors having various current capacities, as shown in FIG. It is also possible to use three or more rectangular copper wires arranged in parallel within a range in which the thickness a of the rectangular copper wires to be formed does not exceed the width b. The E-shaped magnetic core has a central magnetic leg having a columnar shape, but is not limited to this, and may have a polygonal column shape such as a square pole.

[0024]

As described above, according to the present invention,
A small, inexpensive, and highly reliable inductor having a high space factor of the coil, a small number of parts, and no heat generation due to copper loss could be provided.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a coil and a magnetic core used in an inductor according to an embodiment of the present invention. FIG. 1A is a plan view showing a state where one magnetic core is incorporated in a coil.
FIG. 1B is a cross-sectional view showing a state where two magnetic cores are incorporated in the coil. FIG. 1C is a side view showing the magnetic core.

FIG. 2 is an explanatory diagram showing a state in which a coil used in the inductor according to the embodiment of the present invention is molded with resin. FIG.
(A) is a plan view. FIG. 2B is a side view. FIG. 2C is a bottom view. FIG. 2D is a perspective view.

FIG. 3 is an explanatory diagram showing a coil and a magnetic core used in an inductor according to another embodiment of the present invention. FIG. 3 (a)
FIG. 4 is a plan view showing a state where one magnetic core is incorporated in the coil. FIG. 3B is a cross-sectional view showing a state where two magnetic cores are incorporated in the coil.

FIG. 4 is an explanatory diagram of a conventional inductor. FIG. 4A is a plan view. FIG. 4B is a side view.

FIG. 5 is an explanatory view of another example of the conventional inductor. FIG.
(A) is a plan view. FIG. 5B is a side view.

[Explanation of symbols]

 1, 11 Coil 2 Magnetic core (used in the present invention) 3 Molded coil 4 Molded surface 5, 35 Terminal 12 (Cylindrical) magnetic leg 13 Magnetic leg 21 Round copper wire 22 Toroidal magnetic core 33 Magnetic core 34 Bobbin a Thickness (of rectangular copper wire) b Width (of rectangular copper wire)

Claims (3)

[Claims] 1. A coil in which a rectangular copper wire is vertically wound is molded so that both ends of the coil are drawn out, and the both ends are bent along a molded surface to form a molded coil. An inductor having an E-shaped magnetic core having a columnar magnetic leg at the center. 2. An inductor, wherein a magnetic core having an E-shaped cross section is incorporated in a coil in which a rectangular copper wire is vertically wound. 3. The inductor according to claim 1, wherein a coil formed by vertically winding at least two or more rectangular copper wires in parallel in the width direction is used.