JPH11204340A - Coil part and electronic device using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve electrical performances such as low loss, low leakage flux, low heat generation, etc., in the coil parts used for electrical devices, reduce the size in high efficiency and high concentration of magnetic flux, so as to realize high workability by eliminating the need for welding and adhering in the jointing part and vibration as well as high quality, high reliability and power-saving designing. SOLUTION: An I-shaped laminated core 19 formed of a bidirectional electromagnetic steel plate as a central magnetic leg, of which both tip ends are provided with a tapered surface 18 like an almost triangular wedge having an angle of about 45 degrees, is built in a coil bobbin 17 wound with a winding 16. Further, two C-shaped laminated cores 21 formed of a bidirectional electromagnetic steel plate as an outer magnetic leg, of which the inside of both-side magnetic leg is provided with a tapered surface 20 having an angle of about 45 degrees, are built in the coil bobbin 17, and the tapered surfaces of the I- shaped and C-shaped laminated cores 19 and 20 are butted against each other for connection, forming a coil part into closed magnetic circuit of a square-θ shape.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil component used for various electronic devices and an electronic device using the same.

[0002]

2. Description of the Related Art In recent years, coil components such as transformers used in various electronic devices have been reduced in size such as light and thin and small, and have high performance such as low loss, low heat generation, high efficiency and low leakage flux. More action is required.

To meet these demands, a variety of magnetic core configurations have been devised from the past.
For both the core type and the ring core type, the wound core type made of unidirectional magnetic steel sheet was effective, but several W
It is difficult to make it as it becomes a thing of small capacity and it is expensive,
It has been demanded that the electrical characteristics can be improved by improving the configuration of the closed magnetic path in the shape of the butting date of the laminated core having good workability, and that the size can be reduced.

[0004] The prior art will be described below with reference to FIGS. First, according to the drawing, reference numeral 2 denotes a coil bobbin wound with a winding 1 and formed of a synthetic resin, and is an E-shaped laminated core made of a non-oriented electromagnetic steel sheet or a unidirectional electromagnetic steel sheet and laminated to a predetermined thickness. 3 and the I-shaped laminated core 4 are assembled into the coil bobbin 2 and an adhesive is applied to the butting portion 5 of the center magnetic leg of the E-shaped laminated core 3. Were welded 7 and joined to form a closed magnetic circuit in the shape of a star, thereby obtaining a completed product as shown in FIG.

[0005] Further, as a closed magnetic circuit having a similar shape of a sun-shape, there is a structure in which E-shaped laminated cores 8 are assembled and butt-welded as shown in FIG.

Also, as shown in FIG. 15, the I-shaped laminated core 9 is formed in an inverted trapezoidal shape having a tapered surface 10 of about 45 degrees at both ends, and the E-shaped laminated core 11 has a short central magnetic leg 12 and an end surface. Are flat, and both outer magnetic legs 13 are
A taper surface 14 having an angle of about 45 degrees is provided on the inner side of the end, and both tapered surfaces 10 and 14 are abutted and welded to both corners 15 to form a sun-shaped closed magnetic field. Road constructions have also been devised. Of course, before welding, the coil bobbin 2 on which the winding 1 is wound is incorporated in the magnetic leg.

[0007]

However, in the above-described closed magnetic circuit configuration in the shape of a sun, first, the E-shaped laminated core 3
And the butted portions 5 and 6 of the I-shaped laminated core 4 are flat,
Since the width of the magnetic leg and the width of the butted portion are the same, the magnetic resistance is large, and the magnetic flux is hard to flow and leaks easily. In particular, in a sun-shaped closed magnetic path using a unidirectional magnetic steel sheet, the center magnetic leg and both outer magnetic legs of the E-shaped laminated core 3 can be formed in the same direction as the rolling direction.
Since the yoke magnetic leg of the link is formed in a direction perpendicular to the rolling direction, the magnetic leg is opposite to the axis of easy magnetization, and the magnetic loss is large. Therefore, in terms of electrical characteristics, there is a problem that the excitation current, iron loss and leakage flux are large, the efficiency is low, and the temperature rise is also high, so that miniaturization cannot be achieved. There is also a quality problem that the magnetizing force is strong and the vibration is large and a beat is easily generated.

In general, as a countermeasure, a magnetic flux density is designed low in terms of design, or a material having a high silicon content among non-oriented electrical steel sheets is used. In addition, as a measure for low leakage flux, a magnetically shielded shield plate made of a silicon steel plate on the outer periphery of the laminated core or a short ring made of a steel plate on the outer periphery of the coil and the core are provided. As a countermeasure against vibration, the butted portion was coated with an adhesive, welded, or impregnated with varnish. However, when the silicon content of the magnetic steel sheet is increased, the magnetic saturation point is increased, the magnetic flux density cannot be increased, and there are problems such as obstruction of miniaturization, alienation of productivity, and increase in member cost.

As described above, the conventional transformer has a problem in terms of downsizing due to high performance, particularly in terms of power saving design for reducing power consumption and standby power of electronic equipment.

The present invention solves the above-mentioned problems and has high performance, high quality such as low leakage flux, low iron loss, high efficiency, low heat generation, miniaturization, low vibration, no welding joint, and no middle leg adhesion. An object is to provide a coil component that achieves high reliability and high workability.

[0011]

In order to solve the above-mentioned problems, a coil component according to the present invention comprises a coil bobbin on which a winding is wound, and a wedge-shaped wedge-shaped end having a substantially triangular shape as a central magnetic leg incorporated in the coil bobbin. An I-shaped laminated core formed of a bidirectional electromagnetic steel sheet having a tapered surface, and a bidirectional electromagnetic steel sheet having two tapered surfaces provided inside both side magnetic legs which are incorporated into the coil bobbin and serve as both outer magnetic legs. And a C-shaped laminated core having the tapered surfaces joined to each other in two directions by using the tapered surfaces as joining surfaces to form a closed magnetic circuit having a sun-shape.

In the above configuration, as compared with the conventional flat butting method of the E-shaped and I-shaped laminated cores, the abutting portion is only the tapered surface of the center magnetic leg and the outer magnetic leg portion is free. Further, since the contact area of the butted portion is increased, the magnetic resistance at the butted contact surface is reduced, and the magnetic flux passing through the magnetic path is easy to pass through. Therefore, the magnetic flux density near the butted portion is small and the leakage magnetic flux is small. The magnetizing force is small, and the vibration is small.

Further, on the substantially triangular tapered joint abutting surface, the magnetic flux is rotated right and left by 45 degrees, so that the magnetic flux is effectively transmitted into the closed magnetic path, and the leakage flux is small. Also, the material of the I-type and C-type laminated cores has a silicon content of 3%,
Since a bidirectional electrical steel sheet rolled in two directions, that is, a horizontal direction and a direction perpendicular to the horizontal direction, is used, the axis of easy magnetization of the steel sheet extends over the entire circumference of the closed magnetic circuit of the central magnetic leg, both outer magnetic legs, and the yoke magnetic leg. The rolling direction is such that it can be formed in a regulated manner, and the magnetic efficiency is further improved in combination with the joining means of the abutting tapered surface of the laminated core, so that low iron loss and low leakage flux can be achieved. Further, since the magnetic flux density is the lowest at the outer end portion of the butt taper surface, the iron loss loss is extremely small even when welding is performed, and the vibration is small, so that welding is not required.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention according to claim 1 of the present invention has a coil bobbin on which a winding is wound, and a wedge-shaped tapered surface whose both ends are substantially triangular as a central magnetic leg incorporated in the coil bobbin. An I-shaped laminated core made of a bidirectional electromagnetic steel sheet, and a C-shaped laminated core made of a bidirectional electromagnetic steel sheet having two tapered surfaces inside both side magnetic legs incorporated into the coil bobbin and serving as both outer magnetic legs, The tapered surface of the I-shaped laminated core and the tapered surface of the C-shaped laminated core are joined and joined in two directions as a joining surface to form a closed magnetic path in the shape of a sun. Therefore, the magnetic flux rotates at 45 ° at the butting contact surface. Effectively transmitted to the closed magnetic circuit, the core is also rolled in two directions, a right angle direction and a horizontal direction, and an easy axis of magnetization is formed over the entire circumference of the closed magnetic circuit. Possible loss It is intended that can be electrical performance improvement.

According to a second aspect of the present invention, in addition to the first aspect, since the laminated surface of the I-shaped laminated core and the C-shaped laminated core is formed so as to be pressed, a surface pressure is applied to the laminated surface of the core, and a compressive force is applied. Acts to apply tension, whereby the easy axis of magnetization of the bidirectional magnetic steel sheet is subdivided, and iron loss due to eddy current loss can be reduced.

According to a third aspect of the present invention, in addition to the first or second aspect, since the lamination between the I-type laminated core and the C-shaped laminated core is formed by block caulking, the core laminated surface is pressed. In addition to the improvement of the magnetic characteristics, it is possible to reduce the beat vibration, eliminate the need for welding and improve the workability of assembly.

According to a fourth aspect of the present invention, in addition to the first or second aspect, the outer peripheral portions of the magnetic legs of the I-shaped laminated core and the C-shaped laminated core are formed by press-fitting a metal mounting frame. In addition to improving the magnetic properties by pressing between the core laminations, the outer periphery of the core is covered with metal, so that leakage flux can be reduced and welding joining can be eliminated, thereby improving the assembling workability.

According to a fifth aspect of the present invention, the outer periphery of the wound coil bobbin and the outer periphery of the I-shaped laminated core and the C-shaped laminated core are formed by integral molding with a synthetic resin. Filling and solidifying the synthetic resin increases the pressure between the core layers and improves magnetic properties.In addition, low heat generation due to improved heat dissipation, prevention of smoke and fire at abnormal times, prevention of coil disconnection, waterproof insulation, etc. High reliability and quality improvement.

According to a sixth aspect of the present invention, the coil component according to the first aspect is used in a power supply circuit of an electronic device, thereby reducing set power consumption and standby power during operation due to low iron loss and reducing leakage flux. There is no restriction on the mounting position in the inside, and the degree of freedom in design can be improved.

An embodiment of the present invention will be described below with reference to FIGS. In the description, the same parts as those in the related art are denoted by the same reference numerals, and description thereof will be omitted.

(Embodiment 1) FIG. 1 is a perspective view of a coil component, and FIG. 2 is an exploded perspective view. According to the figure, an I-shape formed of a bidirectional electromagnetic steel sheet having a cylindrical bobbin-shaped coil bobbin 17 on which a winding 16 is wound and a substantially triangular wedge-shaped tapered surface 18 provided at both ends with an angle of about 45 degrees. Laminated core 1
9 is inserted and incorporated as a center magnetic leg. Next, in the direction perpendicular to the insertion direction of the wedge-shaped I-shaped laminated core 19, a two-directional magnetic steel sheet is provided which is provided with a tapered surface 20 having an angle of about 45 degrees in advance inside the tips of the magnetic legs on both sides. Two C-shaped laminated cores 21 are symmetrically incorporated into the coil bobbin 17 as outer magnetic legs to form a tapered surface 1 of the I-shaped laminated core 19.
8 and the tapered surface 20 of the C-shaped laminated core 21 as a joining surface.
They are joined to each other from the direction to form a closed magnetic circuit in the shape of a sun.

FIG. 3 is a sectional view of the coil component.
While two C-shaped laminated cores 21 and one I-shaped laminated core 19 interpose the tapered surfaces 18 and 20 of each other as contact surfaces,
Each of the three tapered tip portions 22 finally becomes one linear butted portion, and even in the case of welding and joining, it is possible by one beat welding. Further, in the structure of the coil bobbin 17, the thickness of the bobbin flange 23 around which the winding 16 is wound is also tapered in advance, and when the C-shaped laminated core 21 is inserted, it can be easily inserted at the entrance, and as it goes deeper, It can be hooked on the bobbin flange portion 23 to fix the sliding position, so that it can be easily butted against the I-shaped laminated core 19.

In the conventional EI type core system, when the core is forcibly inserted into a coil having a large outer shape,
Workability was extremely poor, such as damage to the coil. However, in the present invention, since the core insertion direction is different by 90 degrees, workability is good without damaging the coil.

According to experiments, the angles of the tapered surfaces 18, 20 of the I-shaped and C-shaped laminated cores 19, 21 are 45 ° ± 15 °.
In the range of degrees, the concentration of magnetic flux is reduced, which is effective for electrical characteristics such as leakage flux.

According to the present embodiment, when an experiment was confirmed with a 45-degree taper, FIG. 4 shows a distribution diagram of the magnetic flux flowing in the closed magnetic circuit. In the yoke magnetic leg, the magnetic flux flows efficiently in accordance with the rolling direction of the bidirectional magnetic steel sheet. When compared with the conventional EI core system with the same size, the excitation current was about 30
%, About 50% in iron loss, and about 80% in leakage flux. In addition, it is a method of coupling a closed magnetic path in the shape of a sun.
An adhesive is applied and temporarily fixed to the tapered surfaces 18 and 20 of the C-shaped laminated cores 19 and 21, and the tapered tip portion 22 is fixed by welding. However, in the present embodiment, the coil bobbin 17
By providing a stopper 25 for temporarily fixing one I-shaped and two C-shaped laminated cores 19 and 21 at the inlet flange 24 of the cylindrical body of the coil bobbin 17, the adhesive bobbin 17 can be connected to the coil bobbin 17 only by applying an adhesive or impregnating varnish without welding. The butted portions of the core tapered surfaces 18 and 20 can be integrally fixedly connected.

FIG. 5 is a block diagram of a power supply circuit of an electronic device using the coil component of the first embodiment. 26 is a commercial input power supply, 27 is a power transformer according to the present invention, 28 is a bridge rectifier, 29 is a three-terminal regulator, 30 is a load resistor, and 31 is a capacitor. Especially, it is a circuit used for a standby circuit for remote control of a television receiver, audio equipment, an air conditioner indoor unit, a video deck, etc., and a microcomputer drive control circuit for electric equipment.
By using the power transformer of the first embodiment, the input standby power of W is reduced by half to 0.5 W, the leakage flux is reduced by 80%, and the effect of saving power and increasing the degree of design freedom without being restricted by the mounting position is increased. It is a very convenient coil part.

(Embodiment 2) FIGS. 6 and 7 are cross-sectional views of a coil component according to Embodiment 2; Core 32, C
A plurality of block caulks 34 are provided at the positions of the center magnetic leg and both outer magnetic legs of the shaped laminated core 33 and pressure-bonded in the laminating direction. Therefore, with the above configuration, a pressing force is further applied to the core lamination surface as compared with the first embodiment, and in particular, the iron loss can be reduced by about 5 to 10%. The workability is improved, for example, the handling is easy.

(Embodiment 3) FIG. 8 is a perspective view of a coil component according to Embodiment 3, which is the same as Embodiment 1 until a sun-shaped closed magnetic circuit is formed. , The outer circumferences of the magnetic legs of the I-shaped laminated core 19 and the C-shaped laminated core 21 are assembled by press-fitting a mounting frame 35 made of metal.

Therefore, according to the above configuration, a pressing force is applied in the laminating direction of the cores, so that iron loss is reduced and the leakage flux is further reduced because the metal frame 35 serves as a magnetic shield plate. It suppresses beat vibration and enables welding-less operation.

(Embodiment 4) FIG. 9 is a perspective view of a coil component according to Embodiment 4;
A leaf spring 36 made of metal is pressed into contact with both outer magnetic legs of the I-shaped laminated core 21 and a butt joining portion between the tapered surface 18 of the I-shaped laminated core 19 and the tapered surface 20 of the C-shaped laminated core 21 to sandwich the core laminated portion. It is. The aim and effect are the same as those of the third embodiment.

(Embodiment 5) FIG. 10 is a perspective view of a coil component according to Embodiment 5;
Outer circumference of wound coil bobbin 17 and I-shaped laminated core 1
9. The outer periphery of the C-shaped laminated core 21 is integrally molded with a synthetic resin 37.

Therefore, according to the above configuration, the synthetic resin 37 is filled and solidified, so that a pressing force is applied between the core laminations to reduce iron loss, and in particular, by molding the coil, the heat radiation property is improved, and the waterproof insulation is provided. The miniaturization, quality, reliability, and safety are further improved, such as improvement of the performance, realization of no smoke and no ignition at the time of abnormality such as short circuit, and prevention of disconnection of fine wires.

[0033]

As described above, the coil component of the present invention has the following advantages.
Two C-shaped laminated cores and one I-shaped laminated core are formed using a two-way magnetic steel sheet and abutted to form a sun-shaped closed magnetic circuit. The magnetic flux flows in the same direction, reducing magnetic loss.Also, due to the substantially triangular tapered butted portions at both ends, there is no magnetic concentration, the magnetic flux density is low, the magnetic resistance is small, the exciting current and iron loss are low. In particular, the leakage flux is significantly reduced, the power efficiency is improved, the power consumption is significantly reduced, and the size can be reduced.

Further, the magnetizing force of the tapered junction is small, and the magnetostrictive vibration of the core is small. Therefore, the bonding adhesive at the joint is not required, and depending on the joint shape of the joint, the welding operation is not required. Of course, it has the effect of improving quality and productivity such that varnish impregnation for fixing is not required.

Further, in addition to the above, pressing the laminated surface of the I-shaped laminated core or the C-shaped laminated core has an effect of further reducing iron loss.

[0036] In addition, the inter-layer lamination of the I-shaped laminated core or the C-shaped laminated core is caulked with a block, or the outer periphery of the magnetic leg is press-welded to a metal frame or a leaf spring to press the core lamination, thereby reducing the iron. In addition to loss reduction, it has the effect of reducing leakage flux, reducing beat vibration, and improving electrical characteristics such as welding-less, quality, and workability.

The outer circumference of the wound coil bobbin and I
By molding the outer periphery of the C-shaped laminated core integrally with synthetic resin, in addition to reducing iron loss by pressing between the core laminations, improvement of temperature heat dissipation, smokelessness, no ignition, and coil disconnection in abnormal cases It has the effect of improving quality, reliability, such as prevention, beat vibration reduction, and welding-less.

As described above, high performance and power saving design such as high efficiency, low leakage flux, low iron loss, low heat generation and miniaturization can be realized, and high quality such as low vibration, high reliability and welding can be realized. Thus, it is possible to provide a coil component having extremely high industrial value, such as improved workability, such as less lacing and adhesion.

[Brief description of the drawings]

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

FIG. 2 is an exploded perspective view of the coil component.

FIG. 3 is a sectional view of the coil component.

FIG. 4 is a sectional view of a magnetic flux distribution of a closed magnetic circuit of the coil component.

FIG. 5 is a block diagram of a power supply circuit of an electronic device using the coil component.

FIG. 6 is a cross-sectional view of a coil component according to another embodiment.

FIG. 7 is another sectional view of the same.

FIG. 8 is a perspective view of another coil component.

FIG. 9 is a perspective view of another coil component.

FIG. 10 is a perspective view of another coil component.

FIG. 11 is a perspective view of a conventional coil component.

FIG. 12 is an exploded perspective view of a conventional coil component.

FIG. 13 is a sectional view of a conventional coil component.

FIG. 14 is a sectional view of a conventional coil component.

FIG. 15 is a sectional view of a conventional coil component.

[Explanation of symbols]

 Reference Signs List 16 winding 17 coil bobbin 18, 20 tapered surface 19, 32 I-shaped laminated core 21, 33 C-shaped laminated core 22 tapered tip 23 bobbin flange 24 inlet flange 25 stopper 26 commercial input power supply 27 power transformer 28 bridge rectifier 29 3 Terminal regulator 30 Load resistance 31 Capacitor 34 Block caulking 35 Mounting frame 36 Leaf spring 37 Synthetic resin

Claims (6)

[Claims] A coil bobbin on which a winding is wound; an I-shaped laminated core made of a bidirectional electromagnetic steel sheet having a wedge-shaped tapered surface with substantially triangular ends at both ends as a central magnetic leg incorporated in the coil bobbin; A C-shaped laminated core made of a bidirectional electromagnetic steel sheet having a tapered surface inside both side magnetic legs which are incorporated into a coil bobbin and serving as both outer magnetic legs is provided with a tapered surface of the I-shaped laminated core and a C-shaped laminated core of the C-shaped laminated core. A coil component in which tapered surfaces are joined to each other in two directions as joining surfaces to form a closed magnetic path in the shape of a star. 2. The coil component according to claim 1, wherein the laminated surface of the I-shaped laminated core and the C-shaped laminated core is formed so as to be pressed. 3. The method according to claim 1, wherein the lamination between the I-shaped laminated core and the C-shaped laminated core is formed by block caulking.
The coil component described in the above. 4. The coil component according to claim 1, wherein the outer peripheral portions of the magnetic legs of the I-shaped laminated core and the C-shaped laminated core are formed by press-fitting a mounting frame made of metal. 5. The coil component according to claim 1, wherein an outer periphery of the wound coil bobbin and an outer periphery of the I-shaped laminated core and the C-shaped laminated core are integrally molded with synthetic resin. 6. An electronic device using the coil component according to claim 1.